Rocker assembly with tapered reinforcement insert

Abstract

A vehicle rocker assembly includes a rocker structure having an inner sidewall and an outer sidewall defining an elongated hollow interior therebetween. The rocker assembly also includes a rocker insert that extends along the elongated hollow interior of the sill structure. The rocker insert includes a reinforcement member having a metal sheet defining a contoured structure including an upper wall section, a lower wall section, and a bulkhead wall section integrally extending between the upper wall section and the lower wall section. The bulkhead wall section has a tapered shape between an inner edge of the metal sheet facing the inner sidewall of the sill structure and an outer edge of the metal sheet facing the outer sidewall of the sill structure.

Description

[0001] Cross-reference to related applications

[0002] This application claims the benefit of and priority under 35 USC §119(e) to U.S. Provisional Application No. 63 / 452,692, filed on March 16, 2023, the contents of which are incorporated herein by reference in their entirety. Technical Field

[0003] The present disclosure relates to vehicle structural members and reinforcing beams, and more particularly to components such as rocker assemblies, battery trays, and other vehicle frame structures. Background Art

[0004] A vehicle's frame and body structure are designed to support the vehicle and withstand and absorb certain levels of collision force, such as the distance required to prevent intrusion into the vehicle, as required by insurance and other regulatory and legal requirements. Side impacts on vehicles are typically tested using a side pole impact test, which directs significant side impact forces into the vehicle. The vehicle frame primarily absorbs these side impacts at the rocker section, which extends longitudinally along the lower, outboard portion of the vehicle frame, between the front and rear wheels.

[0005] Incorporating a battery tray in the laterally inboard region between opposing rocker sections in electric and hybrid electric vehicles, it is desirable to mitigate side impact forces to reduce the intrusion distance associated with a side impact. For example, it is generally known to increase the stiffness of a vehicle rocker assembly, such as by adding a rocker insert therein. Summary of the Invention

[0006] The present disclosure provides a vehicle structural component, such as a rocker component or rocker assembly, comprising a beam structure, such as a hollow rocker structure, defining an elongated hollow interior. The rocker structure may be formed with a rocker inner portion and a rocker outer portion that together surround the elongated hollow interior. A rocker insert is positioned along the elongated hollow interior of the beam or stationary structure. The rocker insert comprises a reinforcement member formed from sheet metal, wherein the sheet metal defines a corrugated structure having a series of upper wall segments, lower wall segments, and upstanding or bulkhead wall segments interconnecting the upper and lower wall segments. The bulkhead wall segments have a tapered shape between an inner edge of the sheet metal facing the inner sidewall of the rocker structure and an outer edge of the sheet metal facing the outer sidewall of the rocker structure. The tapered bulkhead wall segments provide improved load path distribution and collision energy absorption at the outer side of the beam structure. Among other structural features, the tapered shape and closed corrugated structure provide enhanced resistance to side impact intrusion along the length of the rocker assembly.

[0007] According to one aspect of the present disclosure, a vehicle rocker assembly includes a rocker structure having an inner sidewall and an outer sidewall defining an elongated hollow interior therebetween. The rocker assembly further includes a rocker insert extending along the elongated hollow interior of the rocker structure. The rocker insert includes a reinforcement member having a sheet metal defining a corrugated structure including an upper wall segment, a lower wall segment, and a bulkhead wall segment extending integrally between the upper and lower wall segments. The bulkhead wall segment has a tapered shape between an inner edge of the sheet metal facing the inner sidewall of the rocker structure and an outer edge of the sheet metal facing the outer sidewall of the rocker structure.

[0008] In some examples, the height dimension of the inner edge of the partition wall segment is greater than the height dimension of the outer edge of the partition wall segment. In some embodiments, the upper wall segment and the lower wall segment have opposite tapered shapes that taper in the opposite direction to the tapered shape of the partition wall segment, such that the upper wall segment and the lower wall segment taper from the outer edge of the metal sheet to the inner edge of the metal sheet.

[0009] Additionally, in some examples, the reinforcement member comprises a rib extending parallel to the length of the rocker insert, for example, along the upper wall segment, the lower wall segment, or the bulkhead wall segment. In some embodiments, the rib extends parallel to the outer edge of the sheet metal facing the outer sidewall of the rocker structure between the upper and lower wall segments. In some examples, the rib is an elongated protrusion that reinforces the corresponding bulkhead wall segment. In other examples, the rib is configured as an extrusion-inducing feature. Furthermore, in some embodiments, the bulkhead wall segment comprises two or more ribs extending parallel to each other between the upper and lower wall segments.

[0010] In some examples, the bulkhead wall segments extend integrally from the upper wall segment and are angled away from each other. Additionally, in some examples, the bulkhead wall segments extend integrally from the lower wall segment and are angled away from each other. In some embodiments, the bulkhead wall segments extend from the interconnected upper and lower wall segments at an angle greater than 90 degrees.

[0011] Furthermore, in some examples, the rocker insert further includes an elongated support member attached along an upper wall section and / or a lower wall section of the reinforcement member. In some cases, the elongated support member may have a top wall attached along the upper wall section of the reinforcement member and a bottom wall attached along the lower wall section of the reinforcement member. Additionally, in some examples, the elongated support member may have a top wall connected to the upper wall section of the reinforcement member and a side wall connected to an outer edge of the bulkhead wall section of the reinforcement member. Additionally, in some examples, the elongated support member may have a top wall, side walls, and a bottom wall integrally connected to define a channel, wherein the reinforcement member is positioned along the channel such that the top and bottom walls of the elongated support member are angled relative to each other to conform to the tapered shape of the bulkhead wall section.

[0012] According to another aspect of the present disclosure, a rocker assembly for a vehicle includes a rocker structure having an inner sidewall and an outer sidewall defining an elongated hollow interior therebetween. The rocker assembly also includes a rocker insert extending along the elongated hollow interior of the rocker structure. The rocker insert includes an elongated support member having a top wall section, a side wall section, and a bottom wall section defining a channel. The rocker insert also includes a reinforcement member disposed in the channel. The reinforcement member is formed from a metal sheet defining a wavy structure including a bulkhead wall section extending integrally between the top wall section and the bottom wall section. The bulkhead wall section has a tapered shape from an inner edge of the metal sheet to an outer edge of the metal sheet, the outer edge of which meets the side wall section of the elongated support member.

[0013] According to another aspect of the present disclosure, a rocker insert is provided, the rocker insert being disposed within an elongated hollow interior defined between a rocker interior and a rocker exterior. The rocker insert includes a reinforcement member having a sheet metal portion including an upper wall segment, a lower wall segment, and a bulkhead wall segment that are integrally connected, the segments being separated by a curved portion to define a wavy structure. Pairs of adjacent bulkhead wall segments extend away from each other at an angle greater than 90 degrees from the upper wall segment and the lower wall segment. The bulkhead wall segment has a tapered shape between an inner edge of the sheet metal portion facing the inner sidewall of the rocker structure and an outer edge of the sheet metal portion facing the outer sidewall of the rocker structure.

[0014] 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

[0015] Figure 1 is a side elevational view of a vehicle schematically illustrating a rocker assembly and a battery tray housing;

[0016] Figure 2 is a perspective view of a vehicle schematically illustrating a rocker assembly and other structural components;

[0017] Figure 3 is a cross-sectional view of an example of a vehicle rocker assembly including a rocker insert;

[0018] Figure 4 yes Figure 3 a perspective view of the rocker insert shown;

[0019] Figure 5 It is from Figure 4 a perspective view of the rocker insert taken from opposite sides as shown;

[0020] Figure 6 yes Figure 4 a side view of the rocker insert shown;

[0021] Figure 6A is Figure 6 An enlarged view of the rocker insert taken at section A is shown;

[0022] Figure 7 yes Figure 4 end view of the rocker insert shown;

[0023] Figure 8 is Figure 7 a perspective cross-sectional view of the rocker insert taken at line IIX-IIX shown;

[0024] Figure 8A is Figure 8 An enlarged perspective view of the rocker insert shown taken at section A;

[0025] Figure 9 is a perspective view of a reinforcement member of a rocker insert; and

[0026] Figure 9A is Figure 9 An enlarged perspective view of the reinforcement member taken at section A is shown.

[0027] Like reference numerals refer to like parts throughout the drawings. DETAILED DESCRIPTION

[0028] Referring now to the drawings and illustrative embodiments depicted herein, a beam member for a vehicle 100 (eg, for a vehicle body structure or frame 102) is provided. Figure 1 and Figure 2 The vehicle frame 102 and associated components may have various designs and configurations, such as for different styles and types of vehicles. Figure 1 and Figure 2 As shown, the vehicle frame 102 has various structural components including B-pillars, hinge pillars, floor cross members, roof bows and headers, and other structural components that support the body of the vehicle and protect passengers, engine components, and sensitive electronics from damage in the event of a collision. Figure 1 and Figure 2 As shown, the vehicle may be operated by a propulsion system that utilizes batteries, such as batteries or battery modules, which may be supported in a battery tray 104 located generally between the axles and under the floor to distribute the battery weight and establish a low center of gravity for the vehicle.

[0029] The beam components disclosed herein may be longitudinally oriented structural beams, such as rocker components or battery tray side members, or another structural component that would benefit from some or all of the crash energy management properties provided by the beam component or embodiments thereof. Figure 3 As shown, a vehicle rocker component and associated portion referred to as a rocker assembly 10 includes a rocker structure having one or more panels. Figure 3 The rocker structure shown has a rocker inner portion 12 and a rocker outer portion 14 attached together to surround an interior region along the length of the rocker structure, thereby defining an elongated hollow interior 16. With respect to the rocker inner portion and the rocker outer portion, the terms "inner" and "outer" are made with reference to an inboard or inward-facing direction and an outboard or outward-facing direction on a vehicle, as Figure 2 Oriented in. Figure 3 As shown, the example vehicle rocker assembly 10 is further provided with a rocker insert 40 disposed within the hollow interior 16 to form a reinforced rocker structure. The rocker insert may also be referred to as a reinforcement insert, such as in embodiments where the rocker assembly is external to or unassociated with the beam member of the rocker assembly. Figure 2 The rocker assembly 10 is shown positioned alongside outer sections of the battery tray 104, with the floor cross member attached to the vehicle rocker assembly 10 so as to span laterally over the battery tray 104. Thus, in further embodiments, the beam member may also or instead be provided as a battery tray frame member, such as a longitudinally oriented side wall section of the battery tray.

[0030] Now refer to Figure 3 In the illustrated vehicle rocker assembly 10, the rocker inner 12 has an upper flange 18 and a lower flange 20 extending along the respective upper and lower edges of the rocker inner 12. The rocker inner 12 protrudes inward from the upper and lower flanges 18, 20 to form an outwardly facing concave structure. The rocker outer 14 has a C-shaped cross-section and has flanges 22, 24, which may be referred to as the upper and lower flanges 22, 24. The upper and lower flanges 18, 22, 24 of the rocker inner 12 and rocker outer 14 are attached together, for example, by welding, with the concave structures facing each other. Figure 3The upper and lower flanges 18 , 22 , 20 , 24 of each rocker panel 12 , 14 are shown extending continuously longitudinally along the edge of the rocker member; however, it is contemplated that the flanges may be eliminated in selected areas to facilitate frame attachment or reduce weight.

[0031] like Figure 3 As also shown in FIG, the rocker inner portion 12 and the rocker outer portion 14 are joined together to enclose or otherwise define an elongated hollow interior 16 between the rocker panels 12, 14. The upper flanges 18, 22 and the lower flanges 20, 24 are substantially planar and oriented in a vertical or substantially vertical configuration to provide a substantially continuous contact fit along the length of the rocker assembly. The upper flanges 18, 22 and the lower flanges 20, 24 can be joined together via welding, and preferably spot welding, but it is contemplated that alternative welding methods or joining means, such as adhesives or fasteners, may be used in addition to or in lieu of spot welding in different embodiments of the rocker structure.

[0032] Figure 3 The rocker inner portion 12 of the vehicle rocker assembly 10 is shown having a substantially flat inner wall 26. The inner wall 26 is integrally interconnected at its respective upper and lower ends with corner transitions to an upper wall 28 and a lower wall 30. Figure 3 In the example shown, the corner transition is at an angle of approximately 90 degrees between the inner wall 26 and the lower wall 30, and the corner transition is at an angle of approximately 100 degrees between the inner wall 26 and the upper wall 28. Similarly, the upper wall 28 and the lower wall 30 each have a corner transition that is at an angle of approximately 90 degrees to the upper flange 18 and the lower flange 20, respectively. In other examples, the angles of the corner transitions may be greater than Figure 3 The examples shown are larger or smaller, such as between approximately 40 and 120 degrees, between 70 and 100 degrees, or between 80 and 95 degrees. The corner transition is also defined by a longitudinal and continuous bend in the sheet material forming the rocker inner portion 12, such as a bend imparted by a roll forming process or a progressive stamping process. The sheet material may be sheet metal, such as high strength or ultra-high strength steel or aluminum. Also as shown Figure 3 As shown, the upper flange 18 and the lower flange 20 are substantially flat and oriented in generally parallel alignment with the flat extent of the inner wall 26. The upper wall 28 and the lower wall 30 of the rocker interior 12 may also be substantially flat and substantially parallel to each other or slightly angled to each other, e.g. Figure 3 shown.

[0033] Also like Figure 3As shown in FIG, the rocker outer portion 14 of the vehicle rocker assembly 10 has an outer wall 32 that is substantially flat and integrally interconnected at its respective upper and lower ends with corner transitions to an upper wall 34 and a lower wall 36. The corner transitions between the outer wall 32 and the upper and lower walls 34, 36 are defined by longitudinally continuous bends in the sheet material from which the rocker outer portion 14 is formed. The sheet material may be the same as or different from the rocker inner portion 12 and may comprise sheet metal, such as optimized high-strength steel or aluminum. Similarly, the upper wall 34 also has a corner transition to the upper flange 22, and the lower wall 36 has a corner transition to the lower flange 24, each of which is also defined by a longitudinally continuous bend in the sheet material of the rocker outer portion 14. The angle of the corner transition of the rocker outer portion 14 is approximately 90 degrees, and in other examples, the angle may be greater or lesser, such as approximately between 40 and 120 degrees, between 70 and 100 degrees, or between 80 and 95 degrees.

[0034] Further reference to threshold structures, such as Figure 3 As shown, the upper and lower flanges 22, 24 are substantially planar and oriented parallel to the planar extent of the outer wall 32. The upper and lower walls 34, 36 of the second rocker panel 14 are also substantially planar, but slightly angled from being orthogonal to the outer wall 32 and the flanges 22, 24. With the flanges 18, 20, 22, 24 of the panels 12, 14 attached together, their walls define a substantially rectangular or hexagonal cross-sectional shape; however, it should be understood that additional examples of rocker inserts may have various alternative cross-sectional shapes and different wall configurations (e.g., portions of the inner or outer wall may not be vertically oriented) for corresponding vehicle designs. It is also contemplated that in other examples, the rocker outer and inner portions may each include different configurations and features, such as ribs, pleats, access holes, etc.

[0035] For example Figure 3 The illustrated vehicle rocker assembly 10 includes a rocker insert 40 disposed within and extending along the elongated hollow interior 16 of the rocker structures 12, 14. Figure 3 As shown, the rocker insert 40 is suspended in a generally axially centered position within the hollow interior 16 of the rocker structure. The rocker insert 40 is supported by brackets 58, 60, which are attached to the rocker structure, for example, by welding, fasteners, adhesives, or a combination thereof. In other examples, the rocker insert can be welded or otherwise attached directly to the rocker structure, such as directly to a flange and / or wall of at least one of the rocker panels.

[0036] exist Figures 3 to 8A In the example shown, the rocker insert 40 includes an elongated support member 42 and a reinforcement member 50 supported by the elongated support member 42. Figure 3As shown, the elongated support member 42 has a top wall section 44, a side wall section 46, and a bottom wall section 48 that are integrally connected to define a C-shaped cross-sectional shape. The top wall section 44, the side wall section 46, and the bottom wall section 48 together define a channel along the length of the support member 42, such as Figure 3 As shown, the open side of the channel faces inward. Figures 3 to 7 As shown, the top wall section 44 and the bottom wall section 48 each have a lip 49 at their inner edges that curves toward the channel. The top wall section 44 and the bottom wall section 48 are angled relative to each other to form a tapered shape that is higher on the inner side and lower on the outer side. A reinforcement member 50 is disposed along the channel of the elongated support member 42. In other examples, the support member can have a different cross-sectional shape along its length, such as an L-shape or other non-tapered shape.

[0037] like Figures 5 to 7 As shown, the reinforcement member 50 is formed from sheet metal to define a corrugated structure including a bulkhead wall section 52 extending integrally between a top wall section 66 and a bottom wall section 68 of the reinforcement member 50, the bulkhead wall section together with the top and bottom wall sections forming the corrugated structure. The bulkhead wall section 52 is generally flat and positioned in generally parallel alignment with potential side impact forces so as to withstand the axial load of the side impact forces. Figure 7 As shown, the bulkhead wall section 52 has a tapered shape between an outer edge 54 of the sheet metal that meets the side wall section 46 of the elongated support member 42 and an inner edge 56 of the sheet metal that is generally aligned with the inside edges of the top and bottom wall sections 44 , 48 .

[0038] Reference again Figure 3 , the rocker insert 40 is suspended within the elongated hollow interior 16 of the rocker structure such that the elongated support member 42 and the supported reinforcement member 50 are spaced apart from the inner surfaces of the rocker inner 12 and the rocker outer 14. To support the rocker insert 40 within the hollow interior 16, the rocker assembly 10 includes an upper bracket 58 and a lower bracket 60 attached between the upper flanges 18, 22 and the lower flanges 20, 24 of the rocker structure, respectively. Figure 4 and Figure 5 As shown, three upper brackets 58 are spaced along the length of the rocker insert 40, with the lower portions welded to the top surface of the top wall section 44. The brackets 58 also have a structure that is positioned and secured to the upper flanges 18, 22 ( Figure 3 ) wherein the upper portion is angled relative to the lower portion of the bracket. Similarly, three lower brackets 60 are spaced along the length of the rocker insert 40 wherein the lower portion is positioned and secured to the lower flanges 20, 24 ( Figure 3), and the upper portion is angled relative to the lower portion and welded to the bottom surface of the bottom wall section 48.

[0039] In other examples, there may be more or fewer upper and lower brackets, and the upper and / or lower brackets may be arranged differently or otherwise omitted, such as by having the elongated support member include an integral attachment flange or by having the rocker structure include attachment features or surfaces for attaching the rocker insert directly to the rocker structure. Thus, it is also contemplated that in other examples, the rocker insert may be positioned against a portion of the rocker structure, such as against the inner wall 26 and / or outer wall 32 of the rocker structure. Furthermore, the rocker insert 40 occupies at least 50% of the width between the outer rocker 14 and the inner rocker 12; however, in other examples, the rocker insert may occupy a lesser or greater percentage of that width, such as greater than 70%, greater than 80%, or greater than 90% of the width between the inner and outer rocker sills.

[0040] like Figure 4 and Figure 5 As further shown in FIG, the elongated support member 42 includes access holes 62 formed in the top wall section 44, the side wall section 46, and the bottom wall section 48 along its length. The access holes 62 provide openings for attaching the reinforcement member 50 in the channel formed by the C-shape of the elongated support member 42. For example, the access holes 62 provide access to the interior of the channel for tools to position, support, and / or attach the reinforcement member 50 to the area of ​​the elongated support member 42. The access holes 46 also reduce mass as material is removed. Additionally, as Figure 4 and Figure 5 As shown, welds 64 that attach the reinforcement member 50 to the elongated support member 42 are formed on the top wall section 44 and the bottom wall section 48 at locations vertically aligned with the top wall section 66 and the bottom wall section 68 of the reinforcement member 50. The welds 64 can be formed using spot welding, laser welding, induction welding, etc. In other examples, alternative joining means, such as adhesives or mechanical fasteners, etc., can be used in addition to or instead of welding.

[0041] like Figure 6 and Figure 6A As shown, the reinforcement member 50 is provided by a corrugated structure formed from sheet metal to provide an upper wall section 66, a lower wall section 68, and a bulkhead wall section 52 extending integrally therebetween. Figures 4 to 7 In the example shown, the upper wall section 66 is attached to the top wall section 44 and the lower wall section 68 is attached to the bottom wall section 48 of the elongated support member 42. Figure 6AAs shown, the undulating shape of the reinforcement member 50 is formed by a set of bulkhead wall segments 52a extending downwardly at a slightly forward angle from the front end of the upper wall segment 66 and another set of bulkhead wall segments 52b extending downwardly at a slightly rearward angle from the rear end of the upper wall segment 66. Similarly, one set of bulkhead wall segments 52a extends upwardly at a slightly rearward angle from the rear end of the lower wall segment 68, and another set of bulkhead wall segments 52b extends upwardly at a slightly forward angle from the front end of the lower wall segment 68. The sets of bulkhead wall segments 52a, 52b thus alternate along the length of the reinforcement member 50 to provide the undulating structure.

[0042] Also like Figure 6 and Figure 6A As shown, the bulkhead wall section 52 integrally extends from the interconnected upper and lower wall sections at an angle. The bulkhead wall section 52 extends from the interconnected upper and lower wall sections 66 and 68 at an angle greater than 90 degrees, or an angle between 90 degrees and 140 degrees, or an angle between 100 degrees and 130 degrees, for example Figure 6A As shown, the angle extends at approximately 120 degrees. In other examples, the angle between the bulkhead wall section and the upper and lower wall sections may be larger or smaller and / or may vary at different bulkhead wall sections along the length of the rocker insert.

[0043] like Figure 6 and Figure 6A As further shown in FIG, the reinforcement member 50 comprises a series of metal sheets, each having a corrugated structure and arranged end to end along the length of the channel formed by the elongated support member 42. Figure 6 and Figure 6A The illustrated reinforcement member 50 has five metal sheets, each having four bulkhead wall sections 52, three upper wall sections 66 and two lower wall sections 68. The metal sheets are each formed into a corrugated structure that is generally W-shaped, e.g. Figure 6A As shown, where the upper wall sections 66a, 66b at the respective front and rear ends of the metal sheet have a length that is approximately half the length of the upper wall section 66c at the center of the metal sheet. In another example, a single metal sheet can be used for the reinforcement member along the entire length of the slender support member. For example, a single metal sheet can be stamped in a press / die that is much shorter than the part itself. In this case, similar to a progressive die, the part will move through the press, hitting the press 2-4 times or more to produce the finished part. Alternatively, by using a series of metal sheets that are repeated along the length of the slender support member, the metal sheets can each be stamped identically, such as by stamping in a single die.

[0044] like Figure 7 As shown, the bulkhead wall section 52 has a tapered shape between an outer edge 54 of the sheet metal facing the outer sidewall 32 of the rocker structure and an inner edge 56 of the sheet metal facing the inner sidewall 26 of the rocker structure ( Figure 3 Due to the tapered shape, the height dimension of the inner edge 56 of the bulkhead wall segment 52 is greater than the height dimension of the outer edge 54 of the bulkhead wall segment. The tapered shape is further defined by the upper portion of the bulkhead wall segment, which forms a bend that transitions into the upper wall segment 66 of the reinforcement member 50, wherein the bend at the upper portion of the bulkhead wall segment angles downward from the inside to the outside. Similarly, the lower portion of the bulkhead wall segment forms a bend that transitions into the lower wall segment 68 of the reinforcement member 50, wherein the bend at the lower portion of the bulkhead wall segment angles upward from the inside to the outside.

[0045] Due to the angled bends at the upper and lower portions of the bulkhead wall section 52, as shown Figure 7 As shown, the upper wall section 66 and the lower wall section 68 have a flat shape that meets and follows the flat inner surfaces of the corresponding top wall section 44 and bottom wall section 48. The angled bends thereby position the upper wall section 66, the lower wall section 68, and the bulkhead wall section 52 of the reinforcement member 50 to further define the tapered shape of the reinforcement member 50. The outer edge 54 of the metal sheet may also be located within the channel of the elongated support member 42, for example Figure 7 4, wherein the outer edge 54 of the bulkhead wall segment 52 meets the side wall 46 of the elongated support member to provide a direct load path and a secure fit of the reinforcement member 50 within the elongated support member 42. In other examples, the elongated support member may additionally or alternatively meet the inner edge of the metal sheet.

[0046] The reinforcement member 42 includes features that may strengthen or induce compression (e.g., holes 72, ribs 74, and / or pleats, etc.) to provide certain performance characteristics to the rocker insert and the entire rocker assembly in response to impact forces. Figures 7 to 9A As shown, the reinforcement member 42 includes a rib 74 that extends along the bulkhead wall section 52 in a direction parallel to the length of the rocker insert 40. The rib 74 is located between the upper wall section 66 and the lower wall section 68 (as shown in FIG. Figure 7 As shown in FIG. 5 , the metal sheet extends on the partition wall section 52 in a direction parallel to the outer edge of the metal sheet facing the outer side wall of the rocker structure. Figure 7 and Figure 8As shown, the bulkhead wall segments 52 each include two ribs 74 extending linearly in the direction extending between the upper wall segment 66 and the lower wall segment 68. The ribs 74 are shown as elongated protrusions that can be formed by stamping so that the ribs extend orthogonally to the flat extent of the bulkhead wall segment 52. The ribs 74 reinforce the bulkhead wall segment 52 in the direction in which it extends, which increases the lateral stiffness of the segment due to the tapered shape. In some examples, the ribs can be omitted or otherwise designed differently. In other examples, the ribs are provided as extrusion inducing features. Thus, the ribs can be used to help tune the extrusion and load response of the system, such that different system requirements in other examples may result in changes in the design of these ribs. Furthermore, in some embodiments, the bulkhead wall segment includes two or more ribs extending in parallel between the upper wall segment and the lower wall segment.

[0047] like Figures 8 to 9A As further shown in FIG. 5 , the upper wall section 66 and the lower wall section 68 have opposite tapered shapes that are opposite to the tapered shape of the bulkhead wall section 52, such that the upper wall section 66 and the lower wall section 68 gradually narrow or otherwise decrease in size between the inner edge 72 of the metal sheet and the outer edge 70 of the metal sheet. The top wall section 66 and the bottom wall section 68 may each include ribs or tuning channels 76, 78 that extend longitudinally along the length of the reinforcement member 50. The tuning channels 76, 78 have a depth that extends into the bend that separates the top and bottom wall sections from the bulkhead wall section 52 to increase robustness and stiffness at the bend. However, in some examples, the tuning channels may be omitted or otherwise designed differently. For example, the tuning channels may be used to help tune the squeeze and load response of the system, such that different system requirements in other examples may result in changes to the channels.

[0048] like Figure 6 As shown, the reinforcement member is disposed along the entire length of the rocker insert and, in further examples, may extend along a selected portion of the length of the rocker insert, such as greater than 50% of the length of the rocker insert or greater than 80% of the length of the rocker insert. The top wall section 44 and the bottom wall section 46 of the support member 42 are configured to be supported by the elongated support member 42 to increase the lateral bending strength of the rocker insert when subjected to inside side impact forces. In other words, the integration of the support member with the elongated support member in the described configuration provides a synergistic structural effect that increases the lateral bending strength of the rocker insert, thereby resulting in a lower risk of failure or buckling threshold of the rocker insert during side impact forces, which in turn can increase battery packaging space, resulting vehicle range, and overall vehicle safety.

[0049] Additionally, the reinforcement member can be a single piece or segmented into multiple pieces that are attached to the channel of the first reinforcement member of the rocker insert. The rocker insert can also be a single piece or segmented. The reinforcement member in the illustrated example is formed from a flat sheet metal, such as a steel alloy. The height, depth, and tapered shape of the rocker insert and associated corrugated reinforcement insert can vary between different examples. It is also contemplated that the depth and height of the rocker insert and associated corrugated reinforcement insert can vary along the rocker assembly.

[0050] Unless otherwise specified, it should generally be understood that additional embodiments of the rocker components may have an orientation opposite to that shown and described, e.g., a rocker panel identified as an inner panel may serve as an outer panel, and a rocker panel identified as an outer panel may serve as an inner panel. The cross-sectional shape of the inner and outer panels may vary along the rocker, e.g., by flaring outward at the ends.

[0051] When designing a vehicle rocker assembly with a rocker insert as disclosed herein, the external dimensions of the vehicle rocker assembly can be reduced and the overall weight of the vehicle rocker assembly can be reduced while meeting desired crash and load conditions. The rocker insert can span a partial section of the vehicle rocker assembly or the full length of the rocker assembly so as to extend beyond the rocker assembly into adjacent components and also reinforce the adjacent components. The rocker insert disclosed herein can include an entire vehicle component or can be joined to additional reinforcements or parts of the vehicle component, for example, at a desired section of the vehicle component. Furthermore, in some instances, the rocker assembly can be embodied as a subassembly or as part of a corresponding vehicle component, such as a structural component or a battery tray component, and thus can be designed to withstand various crash forces and support and maintain different load conditions.

[0052] Furthermore, the rocker inserts disclosed herein can be formed from one or more pieces of sheet material, such as by roll-forming sheet metal, to provide a structure having relatively high strength (for shear and axial loads) and low weight compared to conventional rocker panels. This allows the corresponding stationary panel of the vehicle component (if provided) to use less material, occupy less packaging space, and have greater flexibility in external shape design. The cross-sectional shapes of different embodiments of the vehicle component and rocker insert can include a variety of shapes and thicknesses depending on the desired application of the vehicle component.

[0053] It is also contemplated that the internal reinforcements of the disclosed vehicle rocker assemblies can be incorporated into other types of structural beams, such as into frames and structures of automobiles and ships, buildings, storage tanks, furniture, and the like. With respect to vehicle applications, the vehicle components disclosed herein can be incorporated into a variety of applications of different structural components. The vehicle components can be designed to support and withstand different loading conditions, such as for supporting certain horizontal spans or axial loading conditions. Additionally, the vehicle components can be designed to withstand various collision forces, such as for the rocker assemblies shown, column structures, and the like. The cross-sectional geometry, material type selection, and material thickness within the cross-sectional profile of the vehicle component can be configured for this specific application and the desired load and performance characteristics, such as the weight of the vehicle component, beam load capacity, force deflection performance, and collision performance.

[0054] For the purposes of this disclosure, 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 "an embodiment" of the present disclosure is not intended to be interpreted as excluding the existence of additional implementations that also incorporate the recited features. Furthermore, the terms "first," "second," and the like, as used herein, do not denote any order, quantity, or importance, but are used to indicate elements from another.

[0055] The numbers, percentages, ratios, or other values ​​described herein are intended to encompass the recited value, as well as other values ​​that are "about" or "approximately" the recited value, as understood by those of ordinary skill in the art encompassed by the embodiments of the present disclosure. Thus, the recited values ​​should be interpreted as being broad enough to encompass values ​​that are at least close enough to the recited 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 15%, less than 5%, less than 1%, and less than 0.1% of the recited amount.

[0056] Furthermore, it should be understood that any directions or reference frames in the foregoing description are only relative directions or motions. For example, the terms "upper," "lower," "right," "left," "back," "front," "vertical," "horizontal," "inside," "outside" and their derivatives should be understood to mean relative directions or motions. Figure 1 The embodiments of the present invention are shown in the accompanying 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, specific dimensions and other physical characteristics related to the embodiments disclosed herein should not be considered limiting unless expressly stated in the claims.

[0057] The specifically described embodiments may be changed and modified without departing from the principles of the invention, which are limited only by the scope of the appended claims interpreted in accordance with the principles of patent law. The present disclosure has been described in an illustrative manner, and it should be understood that the terminology used is intended to be descriptive rather than restrictive. In light of the above teachings, many modifications and variations are possible in the present disclosure, and the present disclosure may be implemented in a manner other than that specifically described.

Claims

1. A rocker assembly for a vehicle, the rocker assembly comprising: a threshold structure having an inner sidewall and an outer sidewall defining an elongated hollow interior therebetween; as well as a rocker insert extending along the elongated hollow interior of the rocker structure, the rocker insert comprising: a reinforcing member having a metal sheet defining a corrugated structure including an upper wall section, a lower wall section, and a bulkhead wall section extending integrally therebetween; The partition wall section has a tapered shape between an inner edge of the metal sheet facing the inner side wall of the rocker structure and an outer edge of the metal sheet facing the outer side wall of the rocker structure. 2 . The rocker assembly of claim 1 , wherein a height dimension of the inner edge of the bulkhead wall segment is greater than a height dimension of the outer edge of the bulkhead wall segment.

3. The rocker assembly of claim 1 , wherein the upper wall section and the lower wall section have opposite tapered shapes, the tapered shapes being opposite to the tapered shapes of the partition wall sections, such that the upper wall section and the lower wall section gradually narrow between the inner edge of the metal sheet and the outer edge of the metal sheet. 4 . The rocker assembly of claim 1 , wherein the bulkhead wall section includes a reinforcing rib extending linearly in a direction extending between the upper wall section and the lower wall section. The rocker assembly of claim 4 , wherein the reinforcing rib comprises an elongated protrusion.

6. The rocker assembly of claim 1 wherein said bulkhead wall section extends from said interconnected upper and lower wall sections at an angle greater than 90 degrees.

7. The rocker assembly of claim 1, wherein the rocker insert further comprises an elongated support member attached along the upper wall section and / or the lower wall section of the reinforcement member.

8. The rocker assembly of claim 7, wherein the elongated support member includes a top wall attached along the upper wall section of the reinforcement member and a bottom wall attached along the lower wall section of the reinforcement member.

9. The rocker assembly of claim 7, wherein said elongated support member includes a top wall that connects with said upper wall section of said reinforcement member and a side wall that connects with said outer edge of said bulkhead wall section of said reinforcement member.

10. The rocker assembly of claim 7, wherein the elongated support member includes a top wall, side walls, and a bottom wall, the top wall, the side walls, and the bottom wall being integrally connected to define a channel, wherein the reinforcement member is disposed along the channel of the elongated support member, and wherein the top wall and the bottom wall are angled relative to each other to conform to the tapered shape of the bulkhead wall section.

11. A rocker assembly for a vehicle, the rocker assembly comprising: a threshold structure having an inner sidewall and an outer sidewall defining an elongated hollow interior therebetween; as well as a rocker insert extending along the elongated hollow interior of the rocker structure, the rocker insert comprising: an elongated support member having a top wall section, a side wall section, and a bottom wall section defining a channel; as well as a reinforcement member disposed in the channel and comprising a metal sheet defining a corrugated structure including a bulkhead wall section extending integrally between the top wall section and the bottom wall section; wherein the partition wall section has a tapered shape between an inner edge of the metal sheet and an outer edge of the metal sheet, the outer edge meeting the side wall section of the elongated support member.

12. The rocker assembly of claim 11, wherein the corrugated structure of the reinforcement member comprises upper and lower wall sections extending integrally between respective upper and lower ends of the bulkhead wall section.

13. The rocker assembly of claim 12, wherein the upper wall section and the lower wall section have opposite tapered shapes that are opposite to the tapered shape of the bulkhead wall section.

14. The rocker assembly of claim 12, wherein the bulkhead wall section includes a reinforcing rib extending linearly in a direction extending between the upper wall section and the lower wall section.

15. The rocker assembly of claim 14, wherein the reinforcing rib comprises an elongated protrusion.

16. The rocker assembly of claim 12, wherein said bulkhead wall section extends from said interconnected upper and lower wall sections at an angle greater than 90 degrees.

17. The rocker assembly of claim 11, wherein a height dimension of the outer edge of the bulkhead wall section is less than a height dimension of the inner edge of the bulkhead wall section.

18. A rocker insert disposed within an elongated hollow interior defined between a rocker interior and a rocker exterior, the rocker insert comprising: a reinforcing member having a metal sheet comprising an integrally connected upper wall section, a lower wall section, and a bulkhead wall section, the sections being separated by bends so as to define a corrugated structure; wherein pairs of adjacent ones of the bulkhead wall segments extend away from each other at an angle greater than 90 degrees from the upper wall segment and the lower wall segment; and The partition wall section has a tapered shape from an inner edge of the metal sheet facing the inner side wall of the rocker structure to an outer edge of the metal sheet facing the outer side wall of the rocker structure.

19. The rocker insert of claim 18, wherein the rocker insert further comprises an elongated support member having a top wall, side walls, and a bottom wall, the top wall, the side walls, and the bottom wall defining a channel, wherein the reinforcement member is disposed along the channel of the elongated support member, and wherein the top wall and the bottom wall are angled relative to each other to conform to the tapered shape of the partition wall section.

20. A rocker insert according to claim 18, wherein the height dimension of the inner edge of the partition wall segment is greater than the height dimension of the outer edge of the partition wall segment, and wherein the upper wall segment and the lower wall segment have an opposite tapered shape that is opposite to the tapered shape of the partition wall segment, so that the upper wall segment and the lower wall segment gradually narrow between the outer edge of the metal sheet and the inner edge of the metal sheet.

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