Vehicle front longitudinal beam

Abstract

The invention provides a vehicle front side member. A front side member configured to be supported by a vehicle frame includes a tubular body formed of a roll-formed high strength metal and configured to undergo an axial load during a frontal vehicle impact. The high strength metal steel defines a cross-sectional shape along the length of the tubular body. The tubular body includes a central wall extending from a first side wall to a second side wall, the central wall defining at least a first longitudinal hollow channel and a second longitudinal hollow channel. A first crush initiator is disposed in the first sidewall of the tubular body at a first crush region and is formed in the high strength metal prior to roll forming the tubular body. A second crush initiator is disposed in a corner of the tubular body at a second crush region, and is formed in the high strength metal after roll forming the tubular body.

Description

Technical Field

[0001] This disclosure relates to vehicle frame assemblies, and more specifically to the form and assembly of front longitudinal beams for vehicle body structures. Background Technology

[0002] The vehicle frame and body structure are designed to support the vehicle and withstand and absorb a certain degree of impact forces, such as preventing intrusion into the vehicle body according to insurance requirements and other regulations and laws. Frontal collisions are typically tested using front-end crash tests, which direct significant impact forces to the front of the vehicle. The vehicle frame primarily absorbs these frontal collisions through front longitudinal beams and front longitudinal beam assemblies that extend longitudinally between the front bumper and the vehicle's cab.

[0003] The goal is to convert frontal collision forces into other forms of energy in a predictable and controllable manner. Improved forms of front longitudinal beams are desired to achieve goals of crashworthiness, light weight, and efficient material utilization. In the transition to electric vehicles, the presence of the engine in the front section of the vehicle is no longer a given in vehicle design. Therefore, the front longitudinal beam will become increasingly important in absorbing frontal collision energy in a predictable and controlled manner, and opportunities exist to provide improved front longitudinal beams and front longitudinal beam assemblies. Summary of the Invention

[0004] This disclosure provides a front longitudinal beam for a vehicle that absorbs frontal collision energy in a predictable and controlled manner. The front longitudinal beam may comprise a high-strength metal sheet or other rigid material extending longitudinally along its length to form a tubular beam, thereby guiding longitudinal forces between a bumper assembly and a center frame component located at opposite ends of the tubular beam. The tubular beam may have a constant cross-sectional shape and area along its length. Alternatively, the tubular beam may have a substantially constant cross-sectional shape and area along its length, such as in the case of a tapered or angular configuration.

[0005] The front longitudinal beam may be formed from a single continuous material piece (such as a sheet material formed by roll forming, stamping, or a combination thereof). In some instances, the front longitudinal beam may be formed from multiple material pieces joined together. The front longitudinal beam may be formed from multiple single material pieces or multiple material pieces, or it may be formed from a first piece of a first material and a second piece of a second material. One or more edges of the sheet material may be welded or otherwise fixed to form a closed cross-section. The front longitudinal beam may include at least one hollow channel extending longitudinally within the closed cross-section, and in some instances may include two or more hollow channels extending longitudinally within the closed cross-section.

[0006] The front longitudinal beam may be formed with a substantially rectangular cross-sectional shape. In other instances, the front longitudinal beam may be formed with other cross-sectional shapes, such as a substantially rhomboid cross-sectional shape. Furthermore, in some instances, the front longitudinal beam may include an external flange extending outward from the cross-sectional shape. The front longitudinal beam may include one or more grooves or channels projecting inward from the substantially rectangular cross-sectional shape on one or more walls. The cross-sectional shape of the grooves or channels may be square, trapezoidal, circular, or other suitable shapes. The cross-sectional shape of the front longitudinal beam may be configured to withstand axial loads in a frontal collision of the vehicle.

[0007] The front longitudinal beam may include one or more bending initiators. The bending initiator may include one or more holes or corner bends extending laterally and longitudinally disposed at a point along the length of the front longitudinal beam. The bending initiator may be applied to one or more sides of the front longitudinal beam cross-section. The bending initiator may be applied uniformly to a pair of sides of the front longitudinal beam cross-section. The bending initiator may be applied non-uniformly to the sides of the front longitudinal beam cross-section. For example, the bending initiator may form a set of vertically aligned holes.

[0008] The front longitudinal beam may be a structural component for a vehicle frame and comprises a tubular beam of sheet metal rolled along the length of the tubular beam to define a closed cross-sectional shape extending the length of the tubular beam. The tubular beam has a front end configured to connect to a bumper assembly and a rear end configured to connect to a mid-frame component opposite to the front end. The closed cross-sectional shape is configured to withstand axial loads between the front end and the rear end in a frontal collision, such that during axial loads, collision energy is absorbed and converted in a controlled and predictable manner through deformation of the cross-sectional shape along the length of the tubular beam.

[0009] The cross-sectional shape can define a closed shape comprising a hollow channel extending longitudinally along the length of the tubular beam, or a closed shape comprising a plurality of separate hollow channels extending along the length of the tubular beam. The plurality of hollow channels can be separated by a common wall formed from the high-strength metal sheet. Grooves can project inwards into the cross-sectional shape and extend longitudinally in a groove direction, wherein the groove direction is substantially parallel to the length of the tubular beam. Holes extending through the metal sheet can be positioned near a first end of the tubular beam. The tubular beam can be formed by rolling the metal sheet. A first edge and a second edge of the metal sheet can be fixed in the cross-sectional shape at a first engagement position and a second engagement position.

[0010] This disclosure provides a structural beam for a vehicle, comprising an elongated body formed of a sheet metal material. The sheet metal material may be high-strength steel. The body extends from a first end at a bumper assembly to a second end at a center frame assembly, and includes a cross-sectional shape extending the length of the body. The cross-sectional shape may be further defined by a central wall of the sheet metal material and at least one channel formed in the elongated body.

[0011] The outer wall (such as a sidewall portion) of the elongated body may include a plurality of grooves that project inward from the cross-sectional shape and extend longitudinally along a portion of the length of the elongated body. The plurality of grooves may be located adjacent to at least one of the first end or the second end and configured to locally reinforce the elongated body when the structural beam is subjected to axial loads.

[0012] The elongated beam may include a plurality of orifices defining channels extending through the outer and inner walls of the tubular body. The orifices may be positioned adjacent to the plurality of recesses and configured to induce bending of the elongated body when the beam is subjected to an axial load.

[0013] The structural beam may include a first recessed region and a second recessed region in the elongated body. The metal sheet material may include a first edge portion positioned in the first recessed region and a second edge portion positioned in the second recessed region. A first weld joint may be formed between the first edge portion in the first recessed region and the outer wall of the elongated body. A second weld joint may be formed between the second edge portion in the second recessed region and the outer wall of the elongated body. The outer wall of the elongated body may be generally planar aligned.

[0014] The central wall can be constructed in a stepped shape, the stepped shape having a first horizontal portion, a second horizontal portion, and a vertical portion between the first horizontal portion and the second horizontal portion. Multiple fasteners can be attached to the elongated body and disposed on the inner wall of the elongated body. At least one pair of fasteners can be laterally aligned with the vertical portion of the central wall.

[0015] The front longitudinal beam may be configured to be supported by a vehicle frame and include a tubular body formed from a roll-formed high-strength metal sheet and defining a cross-sectional shape. The tubular body may include a central wall extending from a first inner wall to a second inner wall to form at least a first longitudinal channel and a second longitudinal channel extending the length of the tubular body. The outer wall of the tubular body may include a groove extending longitudinally along the length of the tubular body, and an opening may extend through the surface of the tubular body, adjacent to the groove. The tubular body may be configured to withstand axial loads during a frontal collision. Under the axial load, the tubular body may be configured to bend at the opening.

[0016] Embodiments of this disclosure may include one or more of the foregoing features in various combinations. Attached Figure Description

[0017] Figure 1 This is a side view of the vehicle, showing the front longitudinal beams extending between the bumper assembly and the vehicle frame components near the passenger compartment.

[0018] Figure 2 This is a partial perspective view of a partial vehicle frame, which includes a pair of front longitudinal beams extending between an attachment plate of the vehicle bumper assembly and a vehicle frame component near the passenger compartment.

[0019] Figure 3A This is a front perspective side view of an exemplary front longitudinal beam according to this disclosure.

[0020] Figure 3B This is a rear perspective side view of an exemplary front longitudinal beam according to this disclosure.

[0021] Figure 4 yes Figure 3A A side view of an exemplary front longitudinal beam.

[0022] Figure 5 yes Figure 3B A side view of an exemplary front longitudinal beam.

[0023] Figure 6 yes Figure 4 A top view of an exemplary front longitudinal beam.

[0024] Figure 7 yes Figure 4 A bottom view of an exemplary front longitudinal beam.

[0025] Figure 8 yes Figure 6 A cross-sectional view of an exemplary front longitudinal beam taken along line VIII-VIII.

[0026] Figure 9 yes Figure 6An exemplary cross-sectional view of the front longitudinal beam taken along line IX-IX.

[0027] Figure 10 yes Figure 3A An exemplary end perspective side view of the front longitudinal beam.

[0028] Figure 11 yes Figure 3A An exemplary end view of the front longitudinal beam.

[0029] Figure 12 This is a perspective view of an exemplary front longitudinal beam according to this disclosure.

[0030] Figure 13 yes Figure 12 An exemplary end perspective view of the front longitudinal beam.

[0031] Figure 14 This is a perspective view of the second exemplary front longitudinal beam according to this disclosure.

[0032] Figure 15 yes Figure 14 An exemplary end perspective view of the front longitudinal beam.

[0033] Figure 16 This is a perspective view of the third exemplary front longitudinal beam according to this disclosure.

[0034] Figure 17 yes Figure 16 An exemplary end perspective view of the front longitudinal beam.

[0035] Figure 18 This is a perspective view of the fourth exemplary front longitudinal beam according to this disclosure.

[0036] Figure 19 yes Figure 18 An exemplary end perspective view of the front longitudinal beam.

[0037] Figure 20 This is a perspective view of the fifth front longitudinal beam according to this disclosure.

[0038] Figure 21 yes Figure 20 An exemplary end perspective view of the front longitudinal beam.

[0039] Figure 22 This is a perspective view of the sixth exemplary front longitudinal beam according to this disclosure.

[0040] Figure 23 yes Figure 22 An exemplary end perspective view of the front longitudinal beam.

[0041] Figure 24 This is a perspective view of the seventh exemplary front longitudinal beam according to this disclosure.

[0042] Figure 25 yes Figure 24 An exemplary end perspective view of the front longitudinal beam.

[0043] Figure 26 This is a perspective view of the eighth exemplary front longitudinal beam according to this disclosure.

[0044] Figure 27 yes Figure 26 An exemplary end perspective view of the front longitudinal beam.

[0045] Figure 28 This is a perspective view of the ninth exemplary front longitudinal beam according to this disclosure.

[0046] Figure 29 yes Figure 28 An exemplary end perspective view of the front longitudinal beam.

[0047] Figure 30 This is a perspective view of the tenth exemplary front longitudinal beam according to this disclosure.

[0048] Figure 31 yes Figure 30 An exemplary end perspective view of the front longitudinal beam.

[0049] Figure 32 This is a perspective view of the eleventh exemplary front longitudinal beam according to this disclosure.

[0050] Figure 33 yes Figure 32 An exemplary end view of the front longitudinal beam.

[0051] Figure 34 This is a perspective view of the twelfth exemplary front longitudinal beam according to this disclosure.

[0052] Figure 35 yes Figure 34 An exemplary end view of the front longitudinal beam.

[0053] Figure 36 This is a perspective view of the thirteenth exemplary front longitudinal beam according to this disclosure.

[0054] Figure 37 yes Figure 36 An exemplary end view of the front longitudinal beam.

[0055] Figure 38 This is a perspective view of the fourteenth exemplary front longitudinal beam according to this disclosure.

[0056] Figure 39 yes Figure 38 An exemplary end view of the front longitudinal beam.

[0057] Figure 40 This is a perspective view of the fifteenth exemplary front longitudinal beam according to this disclosure.

[0058] Figure 41 yes Figure 40 An exemplary end view of the front longitudinal beam.

[0059] Figure 42 This is a perspective view of the sixteenth exemplary front longitudinal beam according to this disclosure.

[0060] Figure 43 yes Figure 42 An exemplary end view of the front longitudinal beam.

[0061] Figure 44 This is a perspective view of the seventeenth exemplary front longitudinal beam according to this disclosure.

[0062] Figure 45 yes Figure 44 An exemplary end view of the front longitudinal beam.

[0063] Figure 46 This is a perspective view of the eighteenth exemplary front longitudinal beam according to this disclosure.

[0064] Figure 47 yes Figure 46 An exemplary end view of the front longitudinal beam.

[0065] Figure 48 This is a perspective view of the nineteenth exemplary front longitudinal beam according to this disclosure.

[0066] Figure 49 yes Figure 48 An exemplary end view of the front longitudinal beam.

[0067] Figures 50 to 64 Alternative sections that can be implemented using the exemplary front longitudinal beams of this disclosure are shown.

[0068] Figure 65 This is a perspective view of an exemplary front longitudinal beam according to this disclosure.

[0069] Figure 66 yes Figure 65 A perspective view of an exemplary front longitudinal beam.

[0070] Figure 67A yes Figure 65 A top view of an exemplary front longitudinal beam.

[0071] Figure 67B It is intercepted along line LXVII-LXVII. Figure 65 A cross-sectional view of an exemplary front longitudinal beam.

[0072] Figure 68 It is intercepted along line LXVII-LXVII. Figure 67A A cross-sectional view of an exemplary front longitudinal beam.

[0073] Figure 69It is intercepted along line LXIX-LXIX. Figure 67A A cross-sectional view of an exemplary front longitudinal beam.

[0074] Figure 70 This is a perspective view of an exemplary front longitudinal beam according to this disclosure.

[0075] Figure 71 yes Figure 70 A perspective view of an exemplary front longitudinal beam.

[0076] Figure 72A yes Figure 70 A top view of an exemplary front longitudinal beam.

[0077] Figure 72B It is intercepted along line LXXII-LXXII. Figure 70 A cross-sectional view of an exemplary front longitudinal beam.

[0078] Figure 73 It is intercepted along line LXXIII-LXXIII. Figure 72A A cross-sectional view of an exemplary front longitudinal beam.

[0079] Figure 74 It is intercepted along line LXXIV-LXXIV. Figure 72A A cross-sectional view of an exemplary front longitudinal beam.

[0080] Figure 75 It is an exemplary metal sheet prior to roll forming according to this disclosure.

[0081] Figure 76 This is a perspective view of an exemplary front longitudinal beam after the process.

[0082] Details of one or more embodiments of this disclosure are set forth in the accompanying drawings and the following description. Other aspects, advantages, objects, and features will become apparent from the following specification, taken in conjunction with the accompanying drawings, wherein like reference numerals denote like parts. Detailed Implementation

[0083] Structural frames and components used in vehicle structures, such as front longitudinal beams, are disclosed in various embodiments herein as collision energy absorption and management devices, used in conjunction with other vehicle components to absorb and manage collision loads and energy to minimize damage and intrusion during a collision with the vehicle. For example, structural beams can be used between bumper assemblies and center frame assemblies. In some cases, vehicle components may have increased front-end stiffness and collision energy absorption requirements, such as for electric vehicles or vehicles with rear-mounted engines, which have greater vehicle mass and potentially more vulnerable front ends to collision intrusion. While it is known that beams with increased mass in front longitudinal beams can meet increased stiffness requirements, the increased mass typically increases vehicle cost and reduces efficiency. The structural beams disclosed herein can provide increased stiffness; these beams, for example, are formed by rolling a single sheet metal or other rigid material and have anti-collision mechanisms for converting collision forces into other forms of energy in a predictable and controlled manner.

[0084] Referring now to the accompanying drawings and the illustrative embodiments described herein, a front longitudinal beam 10 is provided for a vehicle 100, such as for a body structure or frame 101, such as... Figure 1 and Figure 2 As shown. The vehicle frame 101 and associated components can have various designs and configurations, such as those for different styles and types of vehicles. Figure 1 and Figure 2 As shown, the vehicle frame 101 may include a mid-frame assembly or firewall 102 and bumper assembly 103, as well as other vehicle frame components. The front longitudinal beam 10 may serve as a structural frame component designed to withstand various impact forces and to support and withstand different load conditions. By providing the front longitudinal beam 10 of this disclosure, the size of the front longitudinal beam 10 component and its overall weight can be reduced when designing a vehicle to meet required impact and load requirements. The vehicle 100 may include a pair of front longitudinal beams 10 supporting a front engine compartment. The vehicle 100 may not include a propulsion system with an internal combustion engine, and therefore the front engine compartment may be a front storage compartment. The front longitudinal beams 10 may extend at least a portion of the distance between the front bumper assembly 103 and the firewall 102 or other structural components of the vehicle frame 101.

[0085] Now for reference Figures 3A to 3BThe diagram illustrates a first exemplary front longitudinal beam 20. The front longitudinal beam 20 is a roll-formed structural element formed from a single sheet material piece 22. The longitudinal beam 20 includes a closed cross-sectional shape. The profile of the longitudinal beam 20 defines an elongated body or tubular beam 34, which may be defined by a first sidewall portion 40, a second sidewall portion 42, a top wall portion 44, and a bottom wall portion 46. The first sidewall portion 40 may be located inside the second sidewall portion 42, or, in another instance of the longitudinal beam, conversely, outside the second sidewall portion. The first sidewall portion 40 and the second sidewall portion 42 may be connected via the top wall portion 44 and the bottom wall portion 46. The front end 30 of the beam 34 is configured to connect to a bumper assembly 103 or other vehicle frame component. The rear end 32, opposite the first end 30, is configured to connect to an intermediate frame component, such as a firewall 102 or other vehicle frame component. The cross-sectional shape of the elongated body 34 extends along the length of the body 34 from the front end 30 to the rear end 32. The elongated body 34 may include a central wall 28 extending longitudinally along the length of the body 34, such that the cross-sectional shape includes a plurality of hollow channels defined by the central wall 28. For example, a closed cross-section may include two hollow channels 24, 26 separated by the central wall 28, each of the two hollow channels extending longitudinally along the body 34. Alternatively, the cross-sectional shape may have more or fewer channels.

[0086] The sheet material 22 of the structural beam 34 may comprise any metal or metal alloy having desired properties such as stiffness, tensile strength, etc. For example, the material may comprise aluminum or steel (such as high-strength or ultra-high-strength steel), and combinations of other related metals from different alloys. The sheet material may be wholly or partially non-sheet material, such as injection-molded polymers, composites, aluminum extrusions, or composite pultrusions. The sheet material of the outer beam profile 20 may be formed in a variety of processes, such as cold stamping, roll forming, roll stamping, hot stamping, bending, or combinations thereof. Specific forming processes mentioned herein should be understood as non-limiting. The selection of appropriate forming processes for specific materials and the application of the structural beam 34 of this disclosure can be understood as within the realm of ordinary skill.

[0087] The slender, enclosed shape of the main body 34 is designed to withstand axial loads between the front and rear ends during a frontal collision. For example... Figures 3A to 5 As shown, multiple grooves 36 and orifices 38 can be located on the first sidewall portion 40 of the body 34. Figure 4 ) and the second sidewall portion 42 ( Figure 5 On the ), and configured to serve as a reinforcement and a bending initiator respectively.

[0088] The plurality of recesses 36 include recesses that project inward into the cross-sectional shape and extend longitudinally in the recess direction. The recess direction is substantially parallel to the length of the elongated body 34. One or more recesses may extend along a portion of the length of the elongated body, or in another instance, may extend along the entire or substantially the entire length of the elongated body. The body 34 may include recesses located adjacent to at least one of the first end 30 or the second end 32. For example, the body 34 may include a single recess 36 or more than one recess 36. Near the first end 30, the body 34 may include a recess in the first sidewall portion 40 ( Figure 4 One or more grooves 36 on the second sidewall portion 42 and the second sidewall portion 42 Figure 5 One or more recesses 36 on the first sidewall portion 40. Near the second end 32, the body 34 may include the first sidewall portion 40. Figure 4 One or more grooves 36 on the second sidewall portion 42 and the second sidewall portion 42 Figure 5 One or more grooves 36 on the surface.

[0089] Multiple grooves 36 are formed to selectively increase the strength of the body 34 in areas that serve as reinforcing channels, thereby improving axial load at selected areas of the body 34. The grooves 36 can be selective and localized reinforcement portions of other flat sections of the sheet material 22. The grooves 36 may be locally located near the front end 30 of the bumper assembly 103 facing the vehicle 100, with fewer or no grooves 36 near the rear end 32 of the firewall 102 or intermediate frame assembly facing the vehicle 100. During a frontal collision, the impact force is axially loaded onto the front longitudinal beam 20, giving the grooved sections of the beam increased axial load capacity. The grooves 36 can be formed by a stamping operation before or after forming the cross-sectional structure via roll forming, or they can be formed simultaneously during the roll forming operation.

[0090] Multiple openings 38 include holes or voids in the sheet material 22, extending from the outer wall or surface 48 of the sheet material 22 to the inner wall or surface 50 of the material 22. Figure 9 ).like Figure 3AAs shown, the orifice 38 can be positioned close to the recess 36, such that the orifice 38 is provided and corresponds to the recess 36. For example, the orifice 38 can be positioned close to the end of the corresponding recess 36, such that when the beam is subjected to axial load, the locally reinforced section of the beam in front of the orifice 38 resists failure or buckling before failure at the orifice. The vertically aligned orifices 38 together form effective bending initiation lines B1-B3, such that axial forces cause failure at the bending initiation lines B1-B3, thereby producing controlled bending failure of the beam with desired force deflection characteristics and the desired bending beam position. Thus, the bending initiation lines B1-B3 are located at different positions along the length of the beam on the first sidewall portion compared to the second sidewall portion. Additional orifices 38 can be positioned along the body 34 at different locations that do not correspond to the recess 36, but are located in areas that promote the desired deformation characteristics of the beam, such as on the first sidewall portion 40 or the second sidewall portion 42. Alternatively, the orifice 38 can be positioned on the top wall portion 44 or the bottom wall portion 46.

[0091] Multiple orifices 38 are formed to selectively reduce the strength of the body 34 in areas that serve as bending initiators (such as exemplary bending initiation lines B1-B3). Orifices 38 can be selective and localized weakening portions of the sheet material 22. During a frontal collision of the vehicle and when the collision force is axially applied to the front longitudinal beam 20, the orifices 38 provide selective locations for the collision force to be converted by bending the body 34 at the orifices 38. In other instances, the orifices 38 can be configured as laterally extending angular bends positioned longitudinally along the length of the front longitudinal beam. The orifices 38 can be formed by punching, stamping, or other similar operations after the cross-sectional structure has been formed via roll forming.

[0092] In other instances, the front longitudinal beam may include a crumple initiator, such as at a corner of the beam, which weakens the body at a selective location for the impact force to be converted by causing the body to crumple at the crumple initiator. In some instances, the crumple initiator may be constructed as a void, pit, or locally thinned portion of sheet material.

[0093] Now for reference Figure 4 and Figure 5 The first sidewall portion 40 and the second sidewall portion 42 are shown. The first sidewall portion 40 ( Figure 4 ) and the second sidewall portion ( Figure 5 The first sidewall portion 40 may include a groove 36 and an orifice 38, which serve as reinforcing channels and bending initiators under axially loaded impact forces. Each of the first sidewall portion 40 and the second sidewall portion 42 may additionally include further holes for mounting access points, etc.

[0094] Now for reference Figure 6 and Figure 7 The top wall portion 44 and the bottom wall portion 46 are shown. Top wall portion 44 ( Figure 6 ) and bottom wall portion 46 ( Figure 7 The top wall portion 44 and the bottom wall portion 46 may include additional orifices 38 configured as bending initiators under axially loaded impact forces. Each of these portions may also include additional orifices for mounting access points, etc.

[0095] Now for reference Figure 8 and Figure 9 The following are examples of data from... Figure 6 The cross-sections taken by lines VIII-VIII and IX-IX. The first sidewall portion 40 and the second sidewall portion 42 are connected via a top wall portion 44 and a bottom wall portion 46 to define a closed section of the elongated body 34. The elongated body 34 may comprise, for example, a single sheet material 22 formed by roll forming. Alternatively, the elongated body 34 may comprise more than one plate 22, said plates being attached by welding, adhesives, etc.

[0096] The sheet material 22 includes a first edge portion 52 and a second edge portion 54 extending along the length of the body 34. The first sidewall portion 40 includes a first recessed region 56 extending along the length of the body 34. The first recessed region 56 causes the width of the sheet material 22 to protrude inward, such that the first edge portion 52 of the sheet material is positioned on the outer surface 48 in the first recessed region 56, and the first edge portion 52 and the front wall portion 40 are aligned.

[0097] Similarly, the second sidewall portion 42 includes a second recessed region 58 extending along the length of the body 34. The second recessed region 58 causes the width of the sheet material 22 to project inward, such that when the second edge portion 54 of the sheet material is positioned on the outer surface 48 within the second recessed region 58, the second edge portion 54 and the second sidewall portion 42 are aligned. Figure 8 and Figure 9 As shown, the first sidewall portion 40 and the second sidewall portion 42 are generally aligned in a plane parallel to each other along the length of the main body. The first edge portion 52 and the second edge portion 54 can be attached to the corresponding first recessed region 56 and second recessed region 58 by welding, adhesive, etc. Figure 9 As shown, the first welded joint 60 is formed by the inner surface 50 of the first edge portion 52 and the outer surface 48 of the first recessed region 56. Similarly, the second edge portion 54 can be attached to the second recessed region 58 by welding, adhesive, or the like, such that the second welded joint 62 is formed by the inner surface 50 of the second edge portion 54 and the outer surface 48 of the second recessed region 58.

[0098] A central wall 28 may extend from a first sidewall portion 40 at a first recessed region 56 to a second sidewall portion 42 at a second recessed region 58, passing through the interior of the elongated body 34 and defining a first channel 24 and a second channel 26. The central wall 28 is configured to at least partially pass through or substantially position along an effective longitudinal axis or central load path extending longitudinally along the front longitudinal beam. To accommodate the reinforcing channel 36, the bending initiator hole 38, and the fastener 64 located at the vertical center of the beam, the central wall 28 may be formed from a first vertical position at the first sidewall portion 40 below the vertical center of the beam to a second vertical position at the second sidewall portion 42 above the vertical center of the beam, or in other instances, the opposite. As shown, for example in Figure 8 and Figure 9 In the body 34, the central wall 28 may include a first horizontal portion 72, a second horizontal portion 74, and a vertical portion 76. The vertical portion 76 may connect the first horizontal portion 72 and the second horizontal portion 74 to form a stepped configuration. For example, the first horizontal portion 72 may extend inward from the front wall portion 40 in a direction parallel to the top wall portion 44 and the bottom wall portion 46. The first horizontal portion 72 may be integrally connected to the first recessed region 56 in the lower section 66 of the body 34. The second horizontal portion 74 may extend inward from the rear wall portion 42 in a direction parallel to the top wall portion 44 and the bottom wall portion 46. The second horizontal portion may be integrally connected to the second recessed region 58 in the upper section 70 of the body 34. The lengths of the first horizontal portion 72 and the second horizontal portion 74 may be approximately half the width of the body 34 from the inner wall 50 of the front wall portion 40 to the inner wall 50 of the rear wall portion 42. The vertical portion 76 can extend from the innermost end of the first horizontal portion 72 to the innermost end of the second horizontal portion 74, thereby connecting the first horizontal portion 72 and the second horizontal portion 74. The central wall 28 may include more or fewer horizontal and vertical portions between the front wall portion 40 and the rear wall portion 42. The corner formed between the first horizontal portion 72, the vertical portion 76, and the second horizontal portion 74 provides axial strength to the central wall 28. However, in another embodiment, portions of the central wall may have angular transitions not equal to 90 degrees, such as larger angles to reduce corner bending along the central wall. The central wall 28 may have different shapes, sizes, and locations. The central wall 28 may extend longitudinally along the length of the beam 34. Alternatively, the central wall 28 may be selectively positioned along a portion of the length of the beam 34. The central wall 28 may form a first channel 24 and a second channel 26 in the cross-sectional shape of the beam 34. Alternatively, the central wall 28 may define more or fewer channels in the cross-sectional shape of the beam 34.

[0099] Reference Figure 8Multiple grooves 36 or reinforcing channels protrude inwardly into the cross-sectional shape from the first sidewall portion 40 and the second sidewall portion 42. The grooves 36 facilitate controlled deformation of the elongated body 34 during axial impact loads. The grooves 36 are discontinuous and appear only in discrete, finite portions along the length of the body 34. Figures 3A to 5 In another embodiment, there may be more or fewer grooves 36 along the length of the body 34, and the grooves 36 along the first sidewall portion 40 and the second sidewall portion 42 may have different shapes, sizes, and locations. Furthermore, the grooves 36 have a vertical height and an inward depth, configured to allow the sheet material 22 to form a generally curved shape inward without exceeding the permissible curvature (minimum possible bending radius) of the sheet material 22 without failure.

[0100] refer to Figure 9 The top wall portion 44 and the bottom wall portion 46 may include at least one of a plurality of orifices 38. For example, a first orifice 36 may extend through the sheet material 22 on the top wall portion 44 to define a material void configured to function as a bending initiator of the body 34 during axial loading. A second orifice 36 may extend through the sheet material 22 on the bottom wall portion 46 to define a material void configured to function as a bending initiator of the body 34 during axial loading. The orifices 36 may have different shapes, sizes, and locations along the top wall portion 44 and the bottom wall portion 46.

[0101] refer to Figure 10 and Figure 11 The first sidewall portion 40 and the second sidewall portion 42 may include a plurality of fasteners 64 positioned near the rear end 32 for mounting the front longitudinal beam 20 to the intermediate frame assembly 102. The fasteners 64 are positioned along the height of the body 34 in the lower section 66, upper section 70, and center section 68 to optimize the strength of the connection between the front longitudinal beam 20 and the intermediate frame assembly 102. Alternatively, the beam 34 may include more or fewer fasteners 64, and the fasteners 64 may be positioned at different locations along the height of the beam. A first pair of corresponding fasteners 641 are positioned in the upper section 70 of the first sidewall portion 40 and the second sidewall portion 42 such that they are positioned above the second horizontal portion 74 of the center wall 28. A second pair of corresponding fasteners 643 are positioned in the lower section 66 of the first sidewall portion 40 and the second sidewall portion 42 such that they are positioned below the first horizontal portion 72 of the center wall 28. A third pair of corresponding fasteners 642 are positioned in the center section 68 of the first sidewall portion 40 and the second sidewall portion 42. The third pair of fasteners 642 are laterally aligned with the vertical portion 76 of the center wall 28. The shape of the center wall 28 is configured to define a space such that the third pair of fasteners 643 can be located in the central section 68 without contacting the center wall 28.

[0102] Now for reference Figure 12 and Figure 13 The diagram illustrates a second exemplary front longitudinal beam 120. The front longitudinal beam 120 is a roll-formed structural element formed from a single sheet material 122, shaped to form a closed cross-section with two hollow gaps 124, 126 extending longitudinally and separated by a central wall 128. A first end 130 and a second end 132 of the material 122 are folded inwards into the closed cross-section and can be fixed in place, for example, by resistance spot welding, laser welding, etc.

[0103] The front longitudinal beam 120 includes a collapsing initiator 134 at each of its four edges, located near the first end 136 of the front longitudinal beam 120. When assembled in a vehicle, the first end 136 may be positioned close to the bumper assembly. The front longitudinal beam 120 includes a first bending initiator 138 and a second bending initiator 140. The bending initiators 138 and 140 are spaced apart from each other and positioned closer to the second end 140 than the first end 136. Each bending initiator 138 and 140 produces approximately ½° of bending on two opposite sides. The bending initiators may be in the range of at least ¼° to 2°, or preferably between ½° and less than 1°. The collapsing initiator 134 and the bending initiators 138 and 140 may be formed by a stamping operation after the cross-sectional structure has been formed via roll forming.

[0104] Now for reference Figure 14 and Figure 15 The diagram illustrates a third exemplary front longitudinal beam 150. The front longitudinal beam 150 is generally similar to the second exemplary front longitudinal beam 120, but adds two recesses 152, 154 formed in two opposing sides. Recesses 152, 154 are substantially trapezoidal channels that project inward from a substantially rectangular cross-sectional shape and extend longitudinally along the length of the front longitudinal beam 150. As used herein, the term “substantially” means to provide tolerance for manufacturing tolerances and variability commonly found and understood in automotive components, including structural frame components, and references to numerical, mathematical, or dimensional terms do not need to be perfectly precise. For example, in geometric terms, a rhombus is a shape with perfectly flat straight sides and corner vertices, but an automotive component with a substantially rhomboid cross-sectional shape will have substantially flat sides within manufacturing tolerances for flatness and rounded corners within tolerances for bending radii, which are specified by good manufacturing practices associated with the material, material thickness, and chosen manufacturing process.

[0105] Now for reference Figure 16 and Figure 17The diagram illustrates a fourth exemplary front longitudinal beam 160. The front longitudinal beam 160 is generally similar to the second exemplary front longitudinal beam 120 and the third exemplary front longitudinal beam 150, but adds two recesses 162, 164 formed in two opposing sides, such that each side of the substantially rectangular cross-sectional shape includes one recess. The recesses 162, 164 are substantially trapezoidal channels that project inwards and extend longitudinally along the length of the front longitudinal beam 160.

[0106] Now for reference Figure 18 and Figure 19 The diagram illustrates a fifth exemplary front longitudinal beam 170. The front longitudinal beam 170 is a roll-formed structural element formed from a single sheet material piece 122, shaped to form a closed cross-section with three longitudinally extending hollow voids 172, 174, and 176, separated by two inner walls 178 and 180. A first end 182 of the material 122 terminates inside one of the hollow voids, and a second end 184 terminates tangentially with one of the hollow voids 174. Ends 182 and 184 can be fixed in place, such as by resistance spot welding, laser welding, etc. The front longitudinal beam 170 includes a collapse initiator 134, similar to the second exemplary front longitudinal beam 120 and the third exemplary front longitudinal beam 150. The front longitudinal beam 170 also includes bending initiators 138 and 140, similar to the second exemplary front longitudinal beam 120 and the third exemplary front longitudinal beam 150.

[0107] Now for reference Figure 20 and Figure 21 The diagram illustrates a sixth exemplary front longitudinal beam 190. The front longitudinal beam 190 is a roll-formed structural element formed from two separate sheet metal pieces 192, 194. Each sheet metal piece 192, 194 is roll-formed into a substantially P-shaped cross-section and then oriented in opposite directions for joining by welding or the like. A recess 196 is formed in the P-shaped cross-section such that, when assembled, the ends 198, 200 form a smooth side exterior shape when joined together. The resulting front longitudinal beam 190 includes three hollow voids 202, 204, and 206. The front longitudinal beam 190 includes a collapse initiator 134, similar to the previously described exemplary front longitudinal beam. The front longitudinal beam 190 also includes bending initiators 138, 140, similar to the previously described exemplary front longitudinal beam.

[0108] Now for reference Figure 22 and Figure 23The diagram illustrates a seventh exemplary front longitudinal beam 210. The front longitudinal beam 210 is a structural element formed from two separate sheet material pieces 212, 214. The first piece 212 forms a substantially D-shaped hollow shell and can be formed, for example, by roll forming, extrusion, pultrusion, or other similar processes. The second piece 214 forms an inner wall 216 having a first flange 218 and a second flange 219, thereby separating the hollow shell formed by the first piece 212. Once formed, the second piece 214 can be added to the first piece 212 and secured in place by welding, bonding, or other suitable processes, depending on the material used. The front longitudinal beam 210 includes a collapse initiator 134, similar to the exemplary front longitudinal beams previously described. The front longitudinal beam 210 also includes bending initiators 138, 140, similar to the exemplary front longitudinal beams previously described.

[0109] Now for reference Figure 24 and Figure 25 The diagram illustrates an eighth exemplary front longitudinal beam 220. The front longitudinal beam 220 is a roll-formed structural element formed from a single sheet material piece. The front longitudinal beam 220 includes three hollow gaps 222, 224, and 226 extending longitudinally along its length. The front longitudinal beam 220 includes a double-thickness inner wall 228 to provide increased rigidity for axial loads. Ends 230 and 232 terminate tangentially with the first hollow gap 222 and can be secured in place, for example, by welding (such as resistance spot welding, laser welding, etc.). The front longitudinal beam 220 includes a collapse initiator 134, similar to the previously described exemplary front longitudinal beam. The front longitudinal beam 220 also includes bending initiators 138 and 140, similar to the previously described exemplary front longitudinal beam.

[0110] Now for reference Figure 26 and Figure 27 The diagram illustrates a ninth exemplary front longitudinal beam 240. The front longitudinal beam 240 has a closed, substantially rectangular cross-sectional shape. The front longitudinal beam 240 can be formed by roll forming, extrusion, pultrusion, etc. The front longitudinal beam 240 includes a collapse initiator 134, similar to the previously described exemplary front longitudinal beam. The front longitudinal beam 240 also includes bending initiators 138, 140, similar to the previously described exemplary front longitudinal beam.

[0111] Now for reference Figure 28 and Figure 29 The tenth exemplary front longitudinal beam 250 is shown. The front longitudinal beam 250 is generally similar to the front longitudinal beam 240 of the ninth embodiment, but with the addition of two recesses 252, 254 formed in two opposite sides. The recesses 252, 254 are generally trapezoidal channels that project inward from a generally rectangular cross-sectional shape and extend longitudinally along the length of the front longitudinal beam 250.

[0112] Now for reference Figure 30 and Figure 31The eleventh exemplary front longitudinal beam 260 is shown. The front longitudinal beam 260 is generally similar to the front longitudinal beam 240 of the ninth embodiment and the front longitudinal beam 250 of the tenth embodiment, but with the addition of two recesses 262, 264 formed in two opposing sides, such that each side of the substantially rectangular cross-sectional shape includes a recess. The recesses 262, 264 are substantially trapezoidal channels that project inwards and extend longitudinally along the length of the front longitudinal beam 260.

[0113] Now for reference Figure 32 and Figure 33 The image shows a twelfth exemplary front longitudinal beam 270. The front longitudinal beam 270 is a structural element formed from a single sheet material piece 272, shaped to form a closed cross-section having a single hollow void 274 extending longitudinally along the length of the front longitudinal beam 270. Ends 276, 278 of the sheet material 272 extend outward from the closed cross-section as a single flange 280. The flange 280 may be eccentrically positioned relative to the cross-sectional shape. Ends 276, 278 may be fixed together by welding (such as resistance spot welding, laser welding, etc.). The closed cross-section of the front longitudinal beam 270 defines a substantially parallelogram shape having two pairs of substantially parallel sides arranged with a first pair of acute angles 282 and a second pair of obtuse angles 284. The acute angle 282 may be approximately 87°, and the obtuse angle 284 may be approximately 93°. Among other alternatives, acute angle 282 can be between 80° and 89°, and obtuse angle 284 can be between 91° and 100°.

[0114] Now for reference Figure 34 and Figure 35 The thirteenth exemplary front longitudinal beam 290 is shown. The front longitudinal beam 290 is a structural element similar to the front longitudinal beam 270 described above, having an alternative cross-sectional shape as shown, which extends longitudinally along the length of the front longitudinal beam 290. A first end of the sheet material extends outward from the closed section as a single flange, and a second end of the sheet material is folded inward to form a central wall in the section.

[0115] Now for reference Figure 36 and Figure 37 The fourteenth exemplary front longitudinal beam 310 is shown. The front longitudinal beam 310 is a structural element similar to the front longitudinal beams 270 and 290 described above, having an alternative cross-sectional shape as shown, which extends longitudinally along the length of the front longitudinal beam 310. A first end of the sheet material extends outward from the closed section as a single flange, and a second end of the sheet material is folded inward to form a central wall in the section.

[0116] Now for reference Figure 38 and Figure 39The fifteenth exemplary front longitudinal beam 330 is shown. The front longitudinal beam 330 is a structural element similar to the front longitudinal beams 270-310 described above, having an alternative cross-sectional shape as shown, which extends longitudinally along the length of the front longitudinal beam 330. A first end of the sheet material extends outward from the closed section as a single flange, and a second end of the sheet material is folded inward to form a central wall in the section.

[0117] Now for reference Figure 40 and Figure 41 The sixteenth exemplary front longitudinal beam 350 is shown. The front longitudinal beam 350 is a structural element similar to the front longitudinal beams 270-330 described above, having an alternative cross-sectional shape as shown, which extends longitudinally along the length of the front longitudinal beam 350. A first end of the sheet material extends outward from the closed section as a single flange, and a second end of the sheet material is folded inward to form a central wall in the section.

[0118] Now for reference Figure 42 and Figure 43 The seventeenth exemplary front longitudinal beam 370 is shown. The front longitudinal beam 370 is a structural element similar to the front longitudinal beams 270-350 described above, having an alternative cross-sectional shape as shown, which extends longitudinally along the length of the front longitudinal beam 370. A first end of the sheet material extends outward from the closed section as a single flange, and a second end of the sheet material is folded inward to form a central wall in the section.

[0119] Now for reference Figure 44 and Figure 45 The figure shows the eighteenth exemplary front longitudinal beam 390. The front longitudinal beam 390 is a structural element similar to the front longitudinal beams 270-370 described above, having an alternative cross-sectional shape as shown, which extends longitudinally along the length of the front longitudinal beam 390. The first end of the sheet material extends outward from the closed section as a single flange, and the second end of the sheet material is folded inward to form a central wall in the section.

[0120] Now for reference Figure 46 and Figure 47 The nineteenth exemplary front longitudinal beam 410 is shown. The front longitudinal beam 410 is a structural element similar to the front longitudinal beams 270-390 described above, having an alternative cross-sectional shape as shown, which extends longitudinally along the length of the front longitudinal beam 410. The first end of the sheet material extends outward from the closed section as a single flange.

[0121] Now for reference Figure 48 and Figure 49 The twentieth exemplary front longitudinal beam 430 is shown. The front longitudinal beam 430 is a structural element similar to the front longitudinal beams 270-410 described above, having an alternative cross-sectional shape as shown, which extends longitudinally along the length of the front longitudinal beam 430. A first end of the sheet material extends outward from the closed section as a single flange.

[0122] refer to Figure 50 The cross-sectional shape of the twenty-first exemplary front longitudinal beam 450 is shown. The front longitudinal beam 450 is a structural element similar to the front longitudinal beams 270-430 described above, having an alternative cross-sectional shape as shown, which extends longitudinally along the length of the front longitudinal beam 450.

[0123] refer to Figure 51 The cross-sectional shape of the twenty-second exemplary front longitudinal beam 470 is shown. The front longitudinal beam 470 is a structural element similar to the front longitudinal beams 270-450 described above, having an alternative cross-sectional shape as shown, which extends longitudinally along the length of the front longitudinal beam 470.

[0124] refer to Figure 52 The cross-sectional shape of the twenty-third exemplary front longitudinal beam 490 is shown. The front longitudinal beam 490 is a structural element similar to the front longitudinal beams 270-470 described above, having an alternative cross-sectional shape as shown, which extends longitudinally along the length of the front longitudinal beam 490.

[0125] refer to Figure 53 The cross-sectional shape of the twenty-fourth exemplary front longitudinal beam 510 is shown. The front longitudinal beam 510 is a structural element similar to the front longitudinal beams 270-490 described above, having an alternative cross-sectional shape as shown, which extends longitudinally along the length of the front longitudinal beam 510.

[0126] refer to Figure 54 The cross-sectional shape of the twenty-fifth exemplary front longitudinal beam 530 is shown. The front longitudinal beam 530 is a structural element similar to the front longitudinal beams 270-510 described above, having an alternative cross-sectional shape as shown, which extends longitudinally along the length of the front longitudinal beam 530.

[0127] refer to Figure 55 The cross-sectional shape of the twenty-sixth exemplary front longitudinal beam 550 is shown. The front longitudinal beam 550 is a structural element similar to the front longitudinal beams 270-530 described above, having an alternative cross-sectional shape as shown, which extends longitudinally along the length of the front longitudinal beam 550.

[0128] refer to Figure 56 The cross-sectional shape of the twenty-seventh exemplary front longitudinal beam 570 is shown. The front longitudinal beam 570 is a structural element similar to the front longitudinal beams 270-550 described above, having an alternative cross-sectional shape as shown, which extends longitudinally along the length of the front longitudinal beam 570.

[0129] refer to Figure 57 The cross-sectional shape of the twenty-eighth exemplary front longitudinal beam 590 is shown. The front longitudinal beam 590 is a structural element similar to the front longitudinal beams 270-570 described above, having an alternative cross-sectional shape as shown, which extends longitudinally along the length of the front longitudinal beam 590.

[0130] refer to Figure 58 The cross-sectional shape of the twenty-ninth exemplary front longitudinal beam 610 is shown. The front longitudinal beam 610 is a structural element similar to the front longitudinal beams 270-590 described above, having an alternative cross-sectional shape as shown, which extends longitudinally along the length of the front longitudinal beam 610.

[0131] refer to Figure 59 The cross-sectional shape of the thirtieth exemplary front longitudinal beam 630 is shown. The front longitudinal beam 630 is a structural element similar to the front longitudinal beams 270-610 described above, having an alternative cross-sectional shape as shown, which extends longitudinally along the length of the front longitudinal beam 630.

[0132] refer to Figure 60 The cross-sectional shape of the thirty-first exemplary front longitudinal beam 650 is shown. The front longitudinal beam 650 is a structural element similar to the front longitudinal beams 270-630 described above, having an alternative cross-sectional shape as shown, which extends longitudinally along the length of the front longitudinal beam 650.

[0133] Unless otherwise specified, it should generally be understood that alternative embodiments of the front longitudinal beam may have alternative orientations different from those shown and described, such as when the structure is used as a rear longitudinal beam or side support structure. The front longitudinal beam may be implemented in other alternative configurations, such as mirror images of the structure shown.

[0134] Now for reference Figure 65 and Figure 66Another exemplary front longitudinal beam 820 is shown. The front longitudinal beam 820 is a structural element formed (e.g., via roll forming) from a single sheet material piece 822. The longitudinal beam 820 includes a closed cross-sectional shape. The profile of the longitudinal beam 820 defines an elongated body or tubular beam 834, which may be defined by a first sidewall portion 840, a second sidewall portion 842, a top wall portion 844, and a bottom wall portion 846. The first sidewall portion 840 may be located inside the second sidewall portion 842, or, in another instance of the longitudinal beam, conversely, outside the second sidewall portion. The first sidewall portion 840 and the second sidewall portion 842 may be connected via the top wall portion 844 and the bottom wall portion 846. The front end 830 of the beam 834 is configured to connect to a bumper assembly or other vehicle frame component. The rear end 832, opposite the first end 830, is configured to connect to an intermediate frame component, such as a firewall or other structural component of the vehicle frame. The cross-sectional shape of the elongated body 834 generally extends along the length of the body 834 from the front end 830 to the rear end 832. The elongated body 834 may include a central wall 828 that extends longitudinally along the length of the body 834, such that the cross-sectional shape includes a plurality of hollow channels defined by the central wall 828. For example, a closed cross-section may include two hollow channels 824, 826 separated by the central wall 828, each of the two hollow channels extending longitudinally along the body 834. Alternatively, the cross-sectional shape may have more or fewer hollow channels.

[0135] The sheet material 822 of the structural beam 834 may comprise any metal or metal alloy having desired properties such as stiffness, tensile strength, etc. For example, the material may comprise aluminum or steel (such as high-strength or ultra-high-strength steel), and combinations of other related metals from different alloys. The sheet material may be wholly or partially non-sheet material, such as injection-molded polymers, composites, aluminum extrusions, or composite pultrusions. The sheet material of the outer beam profile 820 may be formed in various processes, including those described below. Figure 75 and Figure 76 The sheet material of the outer beam profile 820 can also be formed in various processes, such as cold stamping, roll forming, roll stamping, hot stamping, bending, or combinations thereof. The specific forming processes mentioned herein should be understood as non-limiting. Selecting a suitable forming process for a particular material and applying the structural beam 834 of this disclosure can be understood as being within the realm of ordinary skill.

[0136] The slender, enclosed shape of the body 834 is designed to withstand axial loads between the front and rear ends during a frontal collision. For example... Figure 65 and Figure 66As shown, the elongated body may include at least one crumple zone having at least one groove configured as a recessed region to induce bending of the elongated body 834 when the tubular beam 820 is subjected to an axial load. For example, the elongated body 834 may include a first crumple zone C1 and a second crumple zone C2. The first crumple zone C1 may include at least one groove located on the second sidewall portion 842. Figure 65 The second collapse region C2 may include the second sidewall portion 842 located on the main body 834. Figure 66 At least one groove of the front longitudinal beam 820. A first crumple zone C1 may be provided on the outer side of the front longitudinal beam 820, and a second crumple zone C2 may be provided on the inner side of the front longitudinal beam 820 to facilitate Z-shaped buckling of the front longitudinal beam 820. The body 834 may include the first crumple zone C1 in a location between the rear end 832 and the middle section of the body 834. The body 834 may include the second crumple zone C2 in a location between the front end 830 and the middle section of the body 834. In other instances, the body may include crumple zones in other locations based on a desired bending location, which may vary based on the vehicle profile.

[0137] In some instances, the first crumple zone C1 and the second crumple zone C2 may include at least one groove 836 disposed on the respective sidewall portions 840, 842, the at least one groove protruding inward into the cross-sectional shape within the crumple zone. The groove 836 may be disposed in the crumple zone where the elongated body 834 is expected to bend under axial load. The first crumple zone C1 and the second crumple zone C2 may include two grooves 836, 838. The first groove 836 may be a circular groove, and the second groove 838 may be an oval groove extending in a groove direction substantially perpendicular to the length of the elongated body 834. The first groove 836 and the second groove 838 may be substantially aligned in the vertical direction within the crumple zone such that the first groove 836 is positioned on the respective sidewall portions 840, 842 directly above or below the second groove 838.

[0138] Vertically aligned grooves 836 and 838 together form an effective bending initiation line B4-B5, causing axial forces to induce failure at the bending initiation line B4-B5, thereby producing controlled bending failure of the beam with desired force deflection characteristics and desired bending beam position. Thus, the bending initiation line B4-B5 is located at a different position along the beam length on the first sidewall portion 840 compared to the second sidewall portion 842. Grooves 836 and 838 are shaped to selectively reduce the strength of the body 834 in areas serving as bending initiators (such as the exemplary bending initiation line B4-B5). Grooves 836 and 838 can be selective and locally weakened portions of sheet material 822. During a frontal collision of the vehicle and when the collision force is axially applied to the front longitudinal beam 820, grooves 836 and 838 provide selective locations for the collision force to be converted by bending the body 834 at the grooves 836 and 838 in the crumple zone.

[0139] Now for reference Figure 67A and Figure 67B The slender body 834 is viewed from the top view and along the sides respectively. Figure 65 The top cross-section of line LXVII-LXVII is shown. In a local region along the length of the elongated body 820, the central wall 828 may include a first shear wall segment 882 and a second shear wall segment 884 separated from the first shear wall segment 882. The separation between the first shear wall segment 882 and the second shear wall segment 884 may define a groove 886 in the central wall 828, which may also be referred to as an opening or aperture formed in the sheet material. The central wall 828 may include more than one groove 886 along the length of the beam 834. The grooves 886 may be aligned with the collapsing regions along the length of the elongated body 834. For example, a first groove 886 may be provided on the central wall 828 at a position aligned with a first collapsing region C1, and a second groove 888 may be provided on the central wall 828 at a position aligned with a second collapsing region C2. The first groove 886 and the second groove 888 can be configured to assist in the initiation of collapse at the desired location by weakening the shear wall at a selective location, so that the slender body 834 can collapse under the impact force.

[0140] Now for reference Figure 68 and Figure 69 This shows the results from... Figure 67A The cross sections cut by lines LXVIII-LXVIII and LXIX-LXIX. Figure 68 A cross-section of the slender body 834, which generally runs along the length of beam 820, is shown. Figure 69A cross-section of an elongated body 834 generally within a first crumple zone C1 is shown. A first sidewall portion 840 and a second sidewall portion 842 are connected via a top wall portion 844 and a bottom wall portion 846 to define a closed cross-section of the elongated body 834. The elongated body 834 may comprise, for example, a single sheet material 822 formed by roll forming. Alternatively, the elongated body 834 may comprise more than one plate 822, said plates being attached by welding, adhesives, or the like.

[0141] The sheet material 822 includes a first edge portion 852 and a second edge portion 854 extending along the length of the body 834. The first sidewall portion 840 includes a first recessed region 856 extending along the length of the body 834. The first recessed region 856 causes the width of the sheet material 822 to protrude inward, such that the first edge portion 852 of the sheet material is positioned on the outer surface 848 in the first recessed region 856, and the first edge portion 852 and the first sidewall portion 840 are aligned.

[0142] Similarly, the second sidewall portion 842 includes a second recessed region 858 extending along the length of the body 834. The second recessed region 858 causes the width of the sheet material 822 to project inward, such that when the second edge portion 854 of the sheet material is positioned on the outer surface 848 in the second recessed region 858, the second edge portion 854 and the second sidewall portion 842 are aligned. Figure 68 and Figure 69 As shown, the first sidewall portion 840 and the second sidewall portion 842 are generally aligned in a plane parallel to each other along the length of the main body. The first edge portion 852 and the second edge portion 854 can be attached to the corresponding first recessed region 856 and second recessed region 858 by welding, adhesive, etc. Figure 68 As shown, the first weld joint 860 is formed by the inner surface 850 of the first edge portion 852 and the outer surface 848 of the first recessed region 856. Similarly, the second edge portion 854 can be attached to the second recessed region 858 by welding, adhesive, or the like, such that the second weld joint 862 is formed by the inner surface 850 of the second edge portion 854 and the outer surface 848 of the second recessed region 858.

[0143] A central wall 828 may extend from a first sidewall portion 840 at a first recessed region 856 to a second sidewall portion 842 at a second recessed region 858, passing through the interior of an elongated body 834 and defining a first channel 824 and a second channel 826. The central wall 828 is configured to pass through or be generally positioned at least partially along an effective longitudinal axis or central load path that extends longitudinally along the front longitudinal beam.

[0144] refer to Figure 69In the first crumple zone C1, grooves 836, 838 protrude inward from the second sidewall portion 842 into the cross-sectional shape, thereby forming a recessed area in the outer periphery of the cross-sectional shape of the elongated beam 834. In other instances, such as in the second crumple zone C2, grooves 836, 838 may protrude from the first sidewall portion 840. Grooves 836, 838 may protrude into the cross-sectional shape, wherein the depth is less than 10 mm, and preferably between 2 mm and 6 mm. Grooves 836, 838 facilitate controlled deformation of the elongated body 834 during axial impact loads. Groove 836 is discontinuous and appears only in discrete, finite portions along the length of the body 834. Figure 65 and Figure 66 In another embodiment, there may be more or fewer grooves 836 along the length of the body 834, and the grooves 836 along the first sidewall portion 840 and / or the second sidewall portion 842 may have different shapes, sizes, and locations. Furthermore, the grooves 836, 838 have a vertical height and an inward depth, configured to allow the sheet material 822 to form a generally curved shape inward without exceeding the permissible curvature (minimum possible bending radius) of the sheet material 822 without failure. The first groove 836 may be generally circular in shape. The second groove 838 may be generally oval in shape and extend in a groove direction perpendicular to the elongated body 834.

[0145] Now for reference Figure 70 and Figure 71Another exemplary front longitudinal beam 920 is shown. The front longitudinal beam 920 is a structural element formed (e.g., via roll forming) from a single sheet material element 922. The longitudinal beam 920 includes a closed cross-sectional shape. The profile of the longitudinal beam 920 defines an elongated body or tubular beam 934, which may be defined by a first sidewall portion 940, a second sidewall portion 942, a top wall portion 944, and a bottom wall portion 946. The first sidewall portion 940 may be located inside the second sidewall portion 942, or, in another instance of the longitudinal beam, conversely, outside the second sidewall portion. The first sidewall portion 940 and the second sidewall portion 942 may be connected via the top wall portion 944 and the bottom wall portion 946. The front end 930 of the beam 934 is configured to connect to a bumper assembly or other vehicle frame component. The rear end 932, opposite the first end 930, is configured to connect to an intermediate frame component, such as a firewall or other vehicle frame component. The cross-sectional shape of the elongated body 934 generally extends along the length of the body 934 from the front end 930 to the rear end 932. The elongated body 934 may include a central wall 928 that extends longitudinally along the length of the body 934, such that the cross-sectional shape includes a plurality of hollow channels at least partially defined by the central wall 928. For example, a closed cross-section may include two hollow channels 924, 926 separated by the central wall 928, each of the two hollow channels extending longitudinally along the body 934. Alternatively, the cross-sectional shape may have more or fewer channels.

[0146] The sheet material 922 of the structural beam 934 may comprise any metal or metal alloy having desired properties such as stiffness, tensile strength, etc. For example, the material may comprise aluminum or steel (such as high-strength or ultra-high-strength steel), and combinations of other related metals from different alloys. The sheet material may be wholly or partially non-sheet material, such as injection-molded polymers, composites, aluminum extrusions, or composite pultrusions. The sheet material of the outer beam profile 920 may be formed in various processes, including those described below. Figure 75 and Figure 76 The sheet material of the outer beam profile 920 can also be formed in various processes, such as cold stamping, roll forming, roll stamping, hot stamping, bending, or combinations thereof. The specific forming processes mentioned herein should be understood as non-limiting. Selecting a suitable forming process for a particular material and applying the structural beam 934 of this disclosure can be understood as being within the realm of ordinary skill.

[0147] The slender, enclosed shape of the body 934 is designed to withstand axial loads between the front and rear ends during a frontal collision. For example... Figure 70 and Figure 71As shown, the elongated body 934 may include at least one crumple zone having at least one groove or recess to induce bending of the elongated body 934 when the tubular beam 920 is subjected to an axial load. At least one groove may protrude into the interior of the cross-sectional shape within the crumple zone. For example, the elongated body 934 may include a first crumple zone C3 and a second crumple zone C4. The first crumple zone C3 may include at least one groove 936 located at the outer corner of the cross-sectional shape, such as a first groove 936 at the corner of the top wall portion 944 and the second side wall portion 942, and a second groove 938 at the corner of the bottom wall portion 946 and the second side wall portion 942. Figure 70 The second crumple zone C4 may include at least one groove 936 located at the outer corner of the cross-sectional shape, such as a first groove 936 at the corner of the top wall portion 944 and the first side wall portion 940 and a second groove 938 at the corner of the bottom wall portion 946 and the first side wall portion 940. Figure 71 The first groove 936 and the second groove 938 can be substantially aligned in the vertical direction in the collapsed area, such that the first groove 936 is positioned directly above or below the second groove 938.

[0148] A first crumple zone C3 may be disposed on the outer side of the front longitudinal beam 920, and a second crumple zone C4 may be disposed on the inner side of the front longitudinal beam 920 to facilitate Z-shaped buckling of the front longitudinal beam 920. The body 934 may include the first crumple zone C3 in a location between the rear end 932 and the midsection of the body 934. The body 934 may include the second crumple zone C4 in a location between the front end 930 and the midsection of the body 934. In other embodiments, the body may include crumple zones in other locations based on a desired bending position, which may vary based on the vehicle profile.

[0149] Vertically aligned grooves 936 and 938 together form an effective bending initiation line B6-B7, causing axial forces to induce failure at the bending initiation line B6-B7, thereby producing controlled bending failure of the beam with desired force deflection characteristics and desired bending beam position. Thus, the bending initiation line B6-B7 is located at a different position along the beam length on the first sidewall portion 940 compared to the second sidewall portion 942. Grooves 936 and 938 are shaped to selectively reduce the strength of the body 934 in areas serving as bending initiators (such as the exemplary bending initiation line B6-B7). Grooves 936 and 938 can be selective and locally weakened portions of sheet material 922. During a frontal collision of the vehicle and when the collision force is axially applied to the front longitudinal beam 920, grooves 936 and 938 provide selective locations for the collision force to be converted by bending the body 934 at the grooves 936 and 938 in the crumple zone.

[0150] Now for reference Figure 72A and Figure 72B The slender body 934 is viewed from the top view and along the sides respectively. Figure 70 The top cross-section of line LXXII-LXXII is shown in the diagram. In a local region along the length of the elongated body 934, the central wall 928 may include a first shear wall segment 982 and a second shear wall segment 984 separated from the first shear wall segment 982. The separation between the first shear wall segment 982 and the second shear wall segment 984 may define a groove 986 in the central wall 928, which may also be referred to as an opening or aperture in the sheet material. The groove 986 may be aligned with one of the collapse regions along the length of the elongated body 934. For example, the groove 986 may be provided on the central wall 928 at a location aligned with the second collapse region. In other instances, the central wall 928 may include more than one groove 986 along the length of the beam 934. The groove 986 may be configured to assist in collapse initiation at a desired location by weakening the shear wall at selective locations, allowing the elongated body 934 to collapse under impact forces.

[0151] Now for reference Figure 73 and Figure 74 The following are examples of data from... Figure 72A The cross sections taken from lines LXXIII-LXXIII and LXXIV-LXXIV. Figure 73 A cross-section of the slender body 934, which generally runs along the length of beam 920, is shown. Figure 74 A cross-section of the elongated body 934 generally within the first crumple zone C3 is shown. A first sidewall portion 940 and a second sidewall portion 942 are connected via a top wall portion 944 and a bottom wall portion 946 to define a closed cross-section of the elongated body 934. The elongated body 934 may comprise, for example, a single sheet material 922 formed by roll forming. Alternatively, the elongated body 934 may comprise more than one plate 922, said plates being attached by welding, adhesives, or the like.

[0152] The sheet material 922 includes a first edge portion 952 and a second edge portion 954 extending along the length of the body 934. The first sidewall portion 940 includes a first recessed region 956 extending along the length of the body 934. The first recessed region 956 causes the width of the sheet material 922 to protrude inward, such that the first edge portion 952 of the sheet material is positioned on the outer surface 948 in the first recessed region 956, and the first edge portion 952 and the first sidewall portion 940 are aligned.

[0153] Similarly, the second sidewall portion 942 includes a second recessed region 958 extending along the length of the body 934. The second recessed region 958 causes the width of the sheet material 922 to project inward, such that when the second edge portion 954 of the sheet material is positioned on the outer surface 948 in the second recessed region 958, the second edge portion 954 and the second sidewall portion 942 are aligned. Figure 73 and Figure 74 As shown, the first sidewall portion 940 and the second sidewall portion 942 are generally aligned in a plane parallel to each other along the length of the main body. The first edge portion 952 and the second edge portion 954 can be attached to the corresponding first recessed region 956 and the second recessed region 958 by welding, adhesive, or the like. The first weld joint 960 is formed by the inner surface 950 of the first edge portion 952 and the outer surface 948 of the first recessed region 956. Similarly, the second edge portion 954 can be attached to the second recessed region 958 by welding, adhesive, or the like, such that the second weld joint 962 is formed by the inner surface 950 of the second edge portion 954 and the outer surface 948 of the second recessed region 958.

[0154] A central wall 928 may extend from a first sidewall portion 940 at a first recessed region 956 to a second sidewall portion 942 at a second recessed region 958, passing through the interior of an elongated body 934 and defining a first channel 924 and a second channel 926. The central wall 928 is configured to pass through or be substantially positioned at least partially along an effective longitudinal axis or central load path that extends longitudinally along the front longitudinal beam.

[0155] refer to Figure 74 In the first crumple zone C3, grooves 936 and 938 protrude inward into the cross-sectional shape at the outer corners, thereby forming recessed areas around the cross-sectional shape at the corners. The first groove 936 protrudes into the upper outer corner where the top wall 944 and the second side wall portion 942 meet. The second groove 938 protrudes into the lower outer corner where the bottom wall 946 and the second side wall portion 942 meet. In other instances, such as in the second crumple zone C4, the grooves may protrude into the upper and lower inner corners where the upper and lower portions meet the first side wall portion. Grooves 936 and 938 facilitate controlled deformation of the elongated body 934 during axial impact loads. Groove 936 is discontinuous and appears only in discrete, finite portions along the length of the body 934. Figure 70 and Figure 71In another embodiment, there may be more or fewer grooves along the length of the body 934, and the grooves 936 along the first sidewall portion 940 and the second sidewall portion 942 may have different shapes, sizes, and locations. Furthermore, the grooves 936, 938 have an inward depth configured to allow the sheet material 922 to form a generally curved shape inward without exceeding the permissible curvature (minimum possible bending radius) of the sheet material 922 without failure.

[0156] refer to Figure 75 and Figure 76 This shows the formation of the reference above. Figures 65 to 74 The method shown and described for an exemplary front longitudinal beam 1020 with grooves. A preferred forming process includes preforming the sidewall portion of the elongated beam ( ) before forming the elongated beam 1034. Figures 65 to 69 The collapsed area on the slender beam 1034 and the groove in the central wall, as well as the post-formed outer corner of the slender beam 1034 after the slender beam 1034 has been formed. Figures 70 to 74 The specific forming process mentioned herein should be understood as non-limiting. The selection of a suitable forming process for a particular material and the application of the structural beam 1034 of this disclosure can be understood as being within the realm of ordinary technology.

[0157] refer to Figure 75 The exemplary front longitudinal beam 1020 can be formed of sheet metal material 1022, which can include any metal or metal alloy having desired properties such as stiffness, tensile strength, etc. For example, the material can include aluminum or steel (such as high-strength or ultra-high-strength steel), and combinations of other related metals from different alloys. Sheet material 1022 can be wholly or partially non-sheet material, such as injection-molded polymers, composites, aluminum extrusions, or composite pultrusions. Figures 65 to 69 As shown, sheet material 1022 can be formed including grooves 1086, 1088 and first collapsible regions 1836, 1838 configured to be positioned on the first and second sidewalls of beam profile 1034. Grooves 1086, 1088 and recesses 1836, 1838 can be formed in various processes, such as cold stamping, roll forming, roll stamping, hot stamping, or combinations thereof. Once the sheet material 1022 is provided with the desired grooves 1086, 1088 and recesses 1836, 1838 for the sidewall portions, the sheet material 1022 can be formed into the elongated beam 1034. Reference Figure 76 Once the slender main body 1034 of beam 1020 is formed, it can be formed as follows: Figures 70 to 74The diagram shows a groove in the outer corner of the beam 1020. In one example, a forming die 1090 may be disposed in the hollow channels 1024, 1026 of the elongated beam 1034. A forming press 1092 may be disposed in the desired crumple zone to press the groove into the elongated beam 1020 at the crumple zone. Thus, the exemplary front longitudinal beam 1020 may be formed having a first set of crumple zones disposed on a first sidewall portion and a second sidewall portion of the elongated beam, and a second set of crumple zones disposed on the outer corner of the elongated beam.

[0158] Therefore, according to this disclosure, the front longitudinal beam can be configured to be supported by the vehicle frame and includes a tubular body formed of roll-formed high-strength metal and configured to withstand axial loads during a frontal collision. The high-strength metal defines a cross-sectional shape along the length of the tubular body. The tubular body includes a central wall extending from a first sidewall to a second sidewall, the central wall defining at least a first longitudinal hollow channel and a second longitudinal hollow channel. A first crumple initiator is disposed in the first sidewall of the tubular body at a first crumple zone and is formed in the high-strength metal prior to roll forming of the tubular body. A second crumple initiator is disposed at a corner of the tubular body at a second crumple zone and is formed in the high-strength metal after roll forming of the tubular body.

[0159] It is also conceivable that the disclosed front longitudinal beam structure can be incorporated into other types of structural beams, such as frames and structures for automobiles and marine vehicles, buildings, storage tanks, furniture, etc. Regarding vehicle applications, the vehicle components disclosed herein can be combined with various applications of different structural components. Vehicle components can be designed to support and withstand different load conditions, such as supporting certain horizontal span or axial load conditions. Furthermore, vehicle components can be designed to withstand various collision forces, such as the illustrated frontal collision, as well as side or rear collisions. The cross-sectional geometry, material type selection, and material thickness within the cross-sectional profile of the vehicle component can be configured for such specific applications and desired load and performance characteristics, such as the weight of the vehicle component, the beam's load-bearing capacity, force deflection performance, and collision performance.

[0160] For the purposes of this disclosure, the articles “a,” “an,” and “described” are intended to mean one or more of the elements present in the foregoing description. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements besides those listed. Furthermore, it should be understood that references to “one embodiment” or “embodiment” in this disclosure are not intended to be construed as excluding the existence of other implementations that also include the listed features. Moreover, the terms “first,” “second,” etc., as used herein, do not indicate any order, quantity, or importance, but are used to refer to elements from another.

[0161] The figures, percentages, ratios, or other values ​​stated herein are intended to include such values, as well as other values ​​for which the terms "about" or "approximately" are used, as are understood by one of ordinary skill in the art as covered by specific embodiments of this disclosure. Therefore, stated values ​​should be interpreted broadly enough to cover values ​​at least sufficiently close to the stated values ​​to perform the desired function or achieve the desired result. For example, the terms "about," "approximately," and "substantially" may refer to amounts less than 5%, less than 1%, less than 0.1%, and less than 0.01% of the stated amount.

[0162] Furthermore, it should be understood that any direction or frame of reference in the preceding description is only relative to direction or motion. For example, the terms “up,” “down,” “right,” “left,” “back,” “front,” “vertical,” “horizontal,” “inner,” “outer,” and their derivatives should be understood in conjunction with… Figure 1 The orientations shown are related. However, it should be understood that various alternative orientations may be provided unless expressly stated otherwise. 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 as defined in the appended claims. Therefore, specific dimensions and other physical characteristics associated with the embodiments disclosed herein should not be considered limiting unless expressly stated otherwise in the claims.

[0163] Changes and modifications may be made to the specifically described embodiments without departing from the principles of the invention, which are intended to be limited only by the scope of the appended claims as interpreted in accordance with the principles of patent law. This 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. Many modifications and variations may be possible with respect to the foregoing teachings, and this disclosure may be practiced in ways other than those specifically described.

[0164] This application is a continuation-in-part of U.S. Utility Patent Application No. 18 / 461,363, filed September 5, 2023, which claims the benefit and priority of U.S. Provisional Patent Application No. 63 / 374,402, filed September 2, 2022, pursuant to 35 USC §119(e), the disclosure of which is considered part of this application and is incorporated herein by reference in its entirety.

Claims

1. A front longitudinal beam for a vehicle frame, the front longitudinal beam comprising: A tubular beam comprising high-strength metal sheet, the tubular beam being formed along its length to define a cross-sectional shape that extends the length of the tubular beam; The tubular beam has a front end configured to connect with a bumper assembly and a rear end opposite the front end and configured to connect with a central frame component. The cross-sectional shape of the tubular beam is configured to withstand axial loads between the front and rear ends during a frontal vehicle collision; and The tubular beam includes at least one of a first collapse initiator along the tubular beam in a first collapse region and a second collapse initiator along the tubular beam in a second collapse region.

2. The front longitudinal beam of claim 1, wherein the cross-sectional shape defines a closed shape, the closed shape comprising a hollow channel extending longitudinally along the length of the tubular beam.

3. The front longitudinal beam of claim 1, wherein the cross-sectional shape defines a closed shape, the closed shape comprising a plurality of separate hollow channels extending longitudinally along the length of the tubular beam.

4. The front longitudinal beam according to claim 3, wherein the plurality of hollow channels are separated by a central wall formed by the high-strength metal sheet.

5. The front longitudinal beam of claim 1, wherein the cross-sectional shape defines a closed shape, the closed shape including a first sidewall, a second sidewall, a top wall and a bottom wall, wherein a central wall extends from the first sidewall to the second sidewall.

6. The front longitudinal beam of claim 5, wherein the first collapse initiator comprises at least one groove disposed in at least one of the first sidewall and the second sidewall, and protrudes into the interior of the cross-sectional shape in the first collapse region.

7. The front longitudinal beam of claim 6, wherein the first collapse initiator comprises a circular groove and a groove extending in the groove direction, wherein the groove direction is substantially perpendicular to the length of the tubular beam, and wherein the circular groove and the groove extending in the groove direction are substantially aligned in the vertical direction in the first collapse region.

8. The front longitudinal beam of claim 1, wherein the second collapse initiator includes a groove formed in at least one corner of the tubular beam in the second collapse region.

9. The front longitudinal beam according to claim 1, wherein the tubular beam is formed by rolling the metal sheet, and the first edge and the second edge of the metal sheet are fixed at the first engagement position and the second engagement position.

10. The front longitudinal beam according to claim 9, wherein the metal sheet is provided with the first collapse initiator before the metal sheet is rolled into shape.

11. The front longitudinal beam according to claim 9, wherein the metal sheet is provided with at least one second collapse initiator after the metal sheet is rolled into shape.

12. The front longitudinal beam according to claim 4, wherein in the first crumple zone and the second crumple zone, the central wall includes a first shear wall segment and a second shear wall segment separated from the first shear wall segment.

13. A structural beam for a vehicle, the structural beam comprising: An elongated body, formed of sheet metal and configured to extend from a first end at a bumper assembly to a second end at a center frame assembly, the elongated body having a cross-sectional shape extending the length of the elongated body; The elongated body includes a plurality of hollow channels formed by the central wall of the metal sheet material, and the elongated body defines the cross-sectional shape. The metal sheet material includes at least a first and a second collapse initiator along a portion of the length of the elongated body, and the first and second collapse initiators are configured to induce bending of the elongated body when the structural beam is subjected to an axial load.

14. The structural beam of claim 13, wherein the cross-sectional shape includes a first sidewall, a second sidewall, a top wall, and a bottom wall, wherein the central wall extends from the first sidewall to the second sidewall.

15. The structural beam of claim 14, wherein the central wall includes a first orifice in a first collapse region defined by the first collapse initiator and a second orifice in a second collapse region defined by the second collapse initiator.

16. The structural beam of claim 14, wherein the metal sheet material comprises high-strength steel, and the elongated body is formed by rolling the metal sheet material.

17. The structural beam of claim 16, wherein the first collapse initiator includes a first recessed region disposed on the first sidewall and a second recessed region disposed on the second sidewall, and the first collapse initiator is formed in the metal sheet material prior to roll forming.

18. The structural beam of claim 16, wherein the second collapse initiator includes at least a first recessed region disposed in the corner of the elongated body, and wherein the second collapse initiator is formed in the sheet metal material after roll forming.

19. A front longitudinal beam configured to be supported by a vehicle frame, the front longitudinal beam comprising: A tubular body, the tubular body being formed from a roll-formed high-strength metal and defining a cross-sectional shape along the length of the tubular body; A central wall extends from a first side wall of the tubular body to a second side wall, thereby defining at least a first longitudinal hollow channel and a second longitudinal hollow channel; A first collapse initiator is disposed in the first sidewall of the tubular body at the first collapse region, and the first collapse initiator is formed in the high-strength metal before the tubular body is rolled. as well as A second collapse initiator is disposed at the corner of the tubular body in the second collapse region. The second collapse initiator is formed in the high-strength metal after the tubular body is rolled and formed. The tubular body is configured to withstand axial loads during a frontal collision with a vehicle.

20. The front longitudinal beam of claim 19, wherein under axial load, the tubular body is configured to bend at the first and second crumple zones.

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