Wave-shaped rocker insert

Abstract

The vehicle rocker assembly may include a sill inner including a sill wall portion, an upper wall portion, a lower wall portion, an upper flange portion, and a lower flange portion. The vehicle rocker assembly may also include a sill outer including a sill wall portion, an upper wall portion, a lower wall portion, an upper flange portion, and a lower flange portion. The vehicle rocker assembly also includes a rocker insert disposed within the elongated hollow interior, the rocker insert including an upper wall, a lower wall, and a sidewall extending between the upper wall and the lower wall. At least one of the upper wall or the lower wall includes a corrugated portion having ridges oriented to extend laterally of the vehicle.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 63 / 363,784, filed April 28, 2022, and U.S. Provisional Patent Application No. 63 / 297,296, filed January 7, 2022, the disclosures of which are considered part of this application and are incorporated by reference herein in their entireties.

[0002] The present disclosure relates to sill assemblies, and more particularly, to rocker inserts for vehicle body structures. [Background technology]

[0003] Vehicle frames and body structures are designed to support the vehicle and to receive and absorb certain levels of impact forces to prevent intrusion into the vehicle in accordance with insurance and other regulatory and legal requirements. Side impacts on vehicles are typically tested with a side pole impact test, which transmits large side impact forces to the vehicle. Vehicle frames primarily absorb these side impacts with rocker sections that run longitudinally between the front and rear wheels along the lower exterior portion of the vehicle frame. In electric and hybrid electric vehicles where battery trays are installed in the lateral interior area between opposing rocker sections, it is desirable to redirect side impact forces away from the battery tray and towards the vehicle floor cross-member. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] U.S. Patent No. 9,493,190 Summary of the Invention [Means for solving the problem]

[0005] The present disclosure provides a vehicle rocker assembly. An example of the vehicle rocker assembly may include a sill inner with a sill wall portion, an upper wall portion, a lower wall portion, an upper flange portion, and a lower flange portion. The vehicle rocker assembly may also include a sill outer with a sill wall portion, an upper wall portion, a lower wall portion, an upper flange portion, and a lower flange portion. The vehicle rocker assembly also includes a rocker insert disposed within the elongated hollow interior. The rocker insert provides a corrugated portion having ridges oriented to extend laterally of the vehicle, the corrugated configuration being configured to stiffen the rocker assembly against lateral impact forces experienced by the vehicle. The corrugated portion is configured to substantially span between the sill wall portions of the sill inner and sill outer during impact to support the elongated hollow interior and improve interior penetration from lateral impact energy.

[0006] Implementations of the present disclosure may include one or more of the following optional features: In some examples, the sidewall is coupled with the sill inner or sill outer to support the rocker insert within the elongated hollow interior. Also, in some implementations, the rocker insert may include a tubular member defined at least in part by an upper wall, a lower wall, and a sidewall, the tubular member defining the hollow interior. In some examples, the rocker insert includes a plastic portion and a metal portion, the metal portion including a corrugated portion, and the plastic portion attached to the metal portion to provide support and attachment features within the elongated hollow interior of the sill inner and sill outer.

[0007] Further, the corrugated portions in some examples are disposed on both the top and bottom surfaces of the upper wall, thereby providing a corrugated shape with the body or thickness of the upper wall. In some examples, the corrugated portions are disposed on both the top and bottom surfaces of the lower wall, thereby similarly providing a corrugated shape with the body or thickness of the lower wall. The corrugated portions may also be disposed on both the top and bottom walls of the reinforcing insert. Further, the upper and lower walls may include metal plates such that the thickness of the metal plates defines the corrugated shape.

[0008] In some examples, the ridges have a V-shape defined by straight line segments that interconnect at relatively sharp bends or junctions. Also, in some implementations, the ridges have a U-shape defined by curved bends or straight line segments that interconnect at junctions. In some examples, the corrugated portion has alternating ridges and grooves that can have different shapes and spacing, such as wave shapes with consistent, different, or varying amplitudes and wavelengths.

[0009] The details of one or more implementations of the disclosure are set forth in the accompanying drawings and the description below. Other aspects, advantages, objects and features will become apparent from a consideration of the following specification in conjunction with the drawings. [Brief description of the drawings]

[0010] [Figure 1] FIG. 2 is a side view of the vehicle, showing a schematic of the rocker assembly and battery tray housing. [Diagram 2] FIG. 1 is a perspective view of a vehicle showing generally the rocker assembly and other structural components. [Diagram 3] FIG. 1 is a cross-sectional view of an example vehicle rocker assembly including a rocker insert. [Figure 4] FIG. 4 is a perspective view of the rocker insert shown in FIG. 3. [Figure 5A] FIG. 5 is a partial enlarged perspective view of the rocker insert shown in section A of FIG. 4. [Figure 5B] FIG. 4 is a partial cross-sectional view of the rocker insert shown in FIG. 3. [Figure 6] FIG. 2 is a cross-sectional view of a vehicle rocker assembly including another example rocker insert. [Figure 7] FIG. 7 is a perspective view of the rocker insert shown in FIG. [Figure 8] FIG. 7 is a graph illustrating the improvement in displacement through the use of the rocker insert shown in FIGS. 3 and 6. [Figure 9] 11 is a cross-sectional view of a vehicle rocker assembly including a further example rocker insert taken along line IX-IX of FIG. 10. [Figure 10] FIG. 10 is a side view of the rocker insert shown in FIG. 9, taken from the inside of the vehicle. [Figure 11] FIG. 10 is a top view of the rocker insert shown in FIG. [Figure 12A] FIG. 12 is a cross-sectional view of the rocker insert taken along line AA in FIG. [Figure 12B] FIG. 11 is a cross-sectional view of the rocker insert taken along line BB in FIG. [Figure 12C] FIG. 11 is a cross-sectional view of the rocker insert taken along line CC in FIG. 10 . [Figure 13] A cross-sectional view of a vehicle rocker assembly including a further example rocker insert taken along line XIII-XIII of Figure 14. [Figure 14] FIG. 14 is a side view of the rocker insert shown in FIG. 13, taken from the inside of the vehicle. [Figure 15] FIG. 14 is a top view of the rocker insert shown in FIG. [Figure 16A] FIG. 16 is a cross-sectional view of the rocker insert taken along line AA in FIG. [Figure 16B] FIG. 15 is a cross-sectional view of the rocker insert taken along line BB in FIG. [Figure 16C] FIG. 15 is a cross-sectional view of the rocker insert taken along line CC in FIG. 14 . [Figure 16D] FIG. 15 is a cross-sectional view of the rocker insert taken along line DD in FIG. [Figure 17] FIG. 13 is a perspective view of another example of a rocker insert. [Figure 18] FIG. 18 is a top view of the rocker insert shown in FIG. 17. [Figure 19] FIG. 18 is a side view of the rocker insert shown in FIG. 17. [Figure 20] FIG. 18 is a bottom view of the rocker insert shown in FIG. 17. [Figure 21] FIG. 20 is a cross-sectional view of the rocker insert taken along line XXI-XXI shown in FIG. [Figure 22]FIG. 13 is a perspective view of another example of a rocker insert. [Figure 23] FIG. 23 is an enlarged view of the rocker insert shown in FIG. 22. [Figure 24] FIG. 23 is a side view of the rocker insert shown in FIG. 22. [Diagram 25] FIG. 24 is a top view of the rocker insert shown in FIG. 23. [Figure 26] FIG. 23 is an exploded view of the rocker insert shown in FIG. [Figure 27] FIG. 26 is a cross-sectional view of the rocker insert taken along the line shown in FIG. 25. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] Like reference numbers refer to like parts throughout the drawings.

[0012] Referring now to the drawings and the illustrative embodiments depicted therein, a rocker assembly is provided for a vehicle 100, such as for a body structure or frame 101 as shown in FIG. 1 and FIG. 2. The vehicle frame 101 and associated components may have various designs and configurations, such as for different styles and models of vehicles. For example, as shown in FIG. 1 and FIG. 2, the vehicle frame has various structural components, including B-pillars 103, hinge pillars 104, floor cross members 105, roof bows 106, and headers 107, among other structural components, that support the body of the vehicle and protect occupants, engine components, and sensitive electronics from damage when subjected to a collision. In some examples, the vehicle may be operated by a propulsion system that uses batteries, such as batteries or battery modules, that may be supported on a battery tray 108, which is generally positioned between the axles and below the floor 109 to distribute the battery weight and establish a low center of gravity for the vehicle.

[0013] The vehicle rocker components include one or more sill panels, such as sill inner panel 12 and sill outer panel 14, attached together around an interior area 16, where the terms "inner" and "outer" refer to the inward or inward facing and outward or outward facing directions on the vehicle, as oriented in FIG. 1. As shown in FIGS. 2 and 3, an example vehicle rocker assembly 10 includes a reinforcing insert disposed in the interior area 16 to form a multi-tubular rocker structure. The rocker assembly 10 shown in FIG. 2 is positioned alongside an outer section of a battery tray 108, where a floor cross member 105 is attached to the vehicle rocker assembly 10 to laterally straddle the battery tray 108. Thus, the vehicle components in additional implementations may also or alternatively be provided as battery tray frame components, such as the longitudinally oriented sidewall sections of the battery tray.

[0014] When designing a vehicle rocker assembly with the rocker inserts disclosed herein, the overall dimensions of the vehicle rocker assembly can be reduced and the overall weight of the vehicle rocker assembly can be reduced while still meeting required impact and load conditions. The rocker inserts can span a partial section of the vehicle rocker assembly or the entire length of the rocker assembly, thereby extending beyond the rocker assembly into and reinforcing adjacent components. The rocker inserts disclosed herein can comprise the entire vehicle component or can be joined to additional reinforcements or portions of the vehicle component, such as at desired sections of the vehicle component. Furthermore, in some examples, the rocker assemblies can be embodied as subassemblies or portions of corresponding vehicle components, such as structural or battery tray components, and as such can be designed to undergo various impact forces and support and withstand different load conditions.

[0015] Additionally, the rocker inserts disclosed herein can be formed from one or more pieces of plate-like material, such as by roll forming sheet metal, to provide a structure having relatively high strength (against shear and axial loads) and low weight compared to typical rocker panels, thereby allowing the corresponding vehicle component steel panels (if provided) to use less material, occupy less packaging space, and have greater flexibility in exterior design. The cross-sectional geometries of different examples of the vehicle component and rocker inserts can include a variety of shapes and thicknesses for the desired application of the vehicle component.

[0016] Unless specified to the contrary, it is generally understood that additional implementations of rocker components may have orientations opposite to those shown and described examples, such as a sill panel identified as an inner panel may be used as an outer panel and a sill panel identified as an outer panel may be used as an inner panel, etc. The cross-sectional shapes of the inner and outer panels may vary along the rocker, such as by flaring outward at the ends.

[0017] Referring now to the vehicle rocker assembly 10 shown in FIG. 3, a first sill panel 12 and a second sill panel 14 are attached together to enclose a hollow interior space 16 between the sill panels 12, 14. The vehicle rocker assembly 10 shown in FIG. 3 is embodied as a vehicle rocker component. Thus, the first sill panel 12 may be referred to as the sill inner panel of the rocker component. The first sill panel 12 has an upper flange 18 and a lower flange 20 that extend along respective upper and lower edges of the inner panel. The first sill panel 12 projects from the upper and lower flanges 18, 20 inwardly of the vehicle to form an outwardly facing concave structure. The second sill panel 14, sometimes referred to as the sill outer panel of the rocker component, has a C-shaped cross section with flanges 22, 24, sometimes also referred to as the upper flange 22 and the lower flange 24. The upper flanges 18, 22 and the lower flanges 20, 24 of the inner and outer sill panels 12, 14 are attached to one another, such as via welding, with their concave structures facing one another. The upper and lower flanges 18, 20, 22, 24 of each of the sill panels 12, 14 shown in Figure 3 extend continuously longitudinally along the edges of the rocker components, however, it is contemplated that the flanges may be trimmed in selected areas to facilitate frame mounting or reduce weight.

[0018] As further shown in FIG. 3, the inner and outer sill panels 12, 14 are joined together to define a hollow interior space 16 between the sill panels 12, 14. The upper and lower flanges 18, 20, 22, 24 are substantially planar and oriented in a generally vertical configuration for generally continuous mating contact along the length of the components. The upper and lower flanges 18, 20, 22, 24 may be joined together via welding, preferably spot welding. However, it is contemplated that alternative welding methods or joining means, such as adhesives or fasteners, etc., may be used in addition to or in place of spot welding in different implementations of the rocker components.

[0019] The first sill panel 12, or inner panel, of the vehicle rocker assembly 10 has an inner wall 26 that is substantially planar. The inner wall 26 is integrally interconnected at its upper and lower ends with corner transitions to an upper wall 28 and a lower wall 30. The corner transitions are approximately 90 degrees between the inner wall 26 and the upper and lower walls 28, 30. The corner transitions are also defined by a longitudinal bend in the sheet material forming the first sill panel 12, such as a metal plate (e.g., an advanced high strength steel plate or an aluminum plate). Similarly, the upper and lower walls 28, 30 each have a corner transition of approximately 90 degrees with the upper flange 18 and the lower flange 20, respectively. The corner transitions are also defined by a longitudinal bend in the sheet material of the first sill panel 12, such as formed by a roll forming process. As also shown in FIG. 3, the upper and lower flanges 18, 20 are substantially planar and oriented in parallel alignment with the planar extent of the inner wall 26. The upper and lower walls 28, 30 of the first sill panel 12 are also substantially planar and substantially parallel to one another as shown in Figure 3, although in additional examples they may be at a slight angle to one another. The corner transitions may also have angle transitions greater or less than that shown in Figure 3, such as approximately 40 degrees to 120 degrees, 70 degrees to 100 degrees, 80 degrees to 95 degrees, or 82 degrees to 92 degrees.

[0020] As also shown in FIG. 3, the second sill panel 14, or outer panel, of the vehicle rocker assembly 10 is substantially planar and has an outer wall 32 integrally interconnected at respective upper and lower ends with an upper wall 34 and a lower wall 36. Approximately 80 degree corner transitions between the outer wall 32 and the upper and lower walls 34, 36 are defined by a longitudinal bend in the sheet material forming the second sill panel 14. The sheet material may be the same or different from the first sill panel 12 and may include a metal plate such as an advanced high strength steel plate or an aluminum plate. Similarly, the upper wall 34 also has a corner transition to the upper flange 22 and the lower wall 36 also has a corner transition to the lower flange 24, each also defined by a longitudinal bend in the sheet material of the second sill panel 14. Again, the corner transitions between the upper and lower walls 34, 36 and the upper and lower flanges 22, 24 and the outer wall 32 may have greater or lesser angular transitions than shown in FIG. 4, such as approximately 40-120 degrees, 70-100 degrees, 80-95 degrees, or 82-92 degrees.

[0021] As shown in FIG. 3, the upper and lower flanges 22, 24 are substantially planar and oriented in parallel alignment with the planar extent of the outer wall 32. The upper and lower walls 34, 36 of the second sill panel 14 are also substantially planar, but angled slightly from perpendicular to the outer wall 32 and the flanges 22, 24. With the flanges 18, 20, 22, 24 of the panels 12, 14 attached together, the walls define a substantially hexagonal cross-sectional shape. However, it is understood that additional examples of rocker inserts may have a variety of alternative cross-sectional shapes (e.g., substantially rectangular shapes) and different wall configurations (e.g., portions of the inner or outer walls that are not vertically oriented) for corresponding vehicle designs. In other examples, it is also contemplated that the outer sill and inner sill may each include different configurations, including, but not limited to, the outer sill having inwardly or outwardly protruding stiffening rib portions configured to provide additional stiffness and side impact support.

[0022] As further shown in Figures 3 and 4, the vehicle rocker assembly 10 includes a rocker insert 40 disposed within the elongated hollow interior 16. The rocker insert 40 includes an upper wall 42, a lower wall 44, and a sidewall 46 extending between the upper wall 42 and the lower wall 44. In some examples, a tubular member 48 is at least partially defined by the upper wall 42, the lower wall 44, and the sidewall 46 to define a hollow interior 50. In some examples, the sidewall 46 is coupled to the sill inner 12 or the sill outer 14 to support the rocker insert 40 within the elongated hollow interior 16. In other examples, opposing sidewalls 46 may couple the upper wall 42 and the lower wall 44, and opposing sidewalls 46 may be coupled to the sill inner 12 and the sill outer 14 to support the rocker insert 40 within the elongated hollow interior 16. In other examples, the rocker insert 40 may include flanges or other additional components configured to be coupled to one or more of the upper wall 42 or the lower wall 44 and the sill inner 12 or the sill outer 14 to support the rocker insert 40 within the elongated hollow interior 16.

[0023] In some examples, one or more of the top wall 42, the bottom wall 44, and the at least one side wall 46 are generally rectangular to include a top surface and a bottom surface joined by opposing sides. In the example shown in FIG. 3, at least one of the top wall 42 and the bottom wall 44 is constructed from steel. Additionally, the side wall 46 may also be constructed from steel. However, it is contemplated that one or more of the top wall 42, the bottom wall 44, or the side wall 46 may be constructed from other materials, including, but not limited to, stainless steel, other metallic materials, and plastic polymeric materials.

[0024] In some examples, one or more of the upper and lower walls 42, 44 are generally rectangular and joined by opposing side walls that are also generally rectangular, but the opposing side walls 46 have a lesser thickness than the upper and lower walls 42, 44. Additionally, in the illustrated example, the upper and lower walls 42, 44 have the same thickness, but other configurations are contemplated, including, but not limited to, the upper wall 42 having a greater thickness than all of the walls below, or the lower wall 44 having a greater thickness than the upper wall 42.

[0025] 5A and 5B, at least one of the top wall 42 or the bottom wall 44 includes a corrugated portion 60. The corrugated portion 60 can be disposed on any surface of the top wall or the bottom wall 44. In some examples, the corrugated portion 60 is disposed on one of the top surface 52 or the bottom surface 54 of the top wall 42. In some examples, the corrugated portion 60 is disposed on both the top surface 52 and the bottom surface 54 of the top wall 42. In other examples, the corrugated portion 60 is disposed on the top surface 53 or the bottom surface 55 of the bottom wall 44. In some examples, the corrugated portion 60 is disposed on both the top surface 53 and the bottom surface 55 of the bottom wall 44. In still other examples, the corrugated portion 60 is disposed on both the top surface 52, 53 and the bottom surface 54, 55 of both the top wall 42 and the bottom wall 44. It is further contemplated that one or more surfaces of one or more of the opposing side walls 46 may include the corrugated portion 60 as well. It is further contemplated that the top surface 52 and the bottom surface 54 may be the same or different. It is further contemplated that the top surface 53 and the bottom surface 55 of the bottom wall 44 may be the same or different. It is further contemplated that the top surface 52 of the top wall 42 and the top surface 53 of the bottom wall 44 may be the same or different, and / or the bottom surface 54 of the top wall 42 and the bottom surface 55 of the bottom wall 44 may be the same or different.

[0026] In some examples, the corrugated portion 60 includes alternating ridges 62 and grooves 64. In the example shown in FIG. 5A and FIG. 5B, the corrugated portion 60 has ridges 62 oriented to extend in a lateral direction of the vehicle. The lateral direction of the vehicle generally extends across the width dimension of the vehicle. In contrast, the longitudinal direction of the vehicle generally extends along the length dimension of the vehicle. In some examples, the peaks 66 of the ridges 62 may be disposed in a generally horizontal plane. The ridges 62 of the corrugated portion 60 are configured to be oriented to generally align with an expected lateral impact against the side of the vehicle to provide increased stiffness to the corresponding portion of the upper or lower wall 44 of the rocker insert 40. Furthermore, the ridges 62 of the corrugated portion 60 extend at least partially between the sill wall portion of the sill inner 12 and the sill outer 14. In some examples, the corrugated portion 60 may be disposed across the entire surface or only a portion of the surface. The ridges 62 and grooves 64 may be of any shape and profile desired, including, but not limited to, the ridges 62 being V-shaped or U-shaped and / or the grooves 64 being V-shaped or U-shaped. It is also contemplated that the ridges 62 and grooves 64 may be the same shape or different shapes from one another, as desired. It is further contemplated that the ridges 62 and / or grooves 64 may be a single repeating shape, alternating shapes, or any pattern, as desired.

[0027] In some examples, the height of the apex 66 of the ridge 62 is the same as the depth of the nadir 68 on the groove. However, it is also contemplated that the height of the apex 66 and the depth of the nadir 68 on the groove 64 may differ from one another such that the height of the apex 66 of the ridge 62 is greater than the depth of the nadir 68 on the groove 64 or vice versa. It is further contemplated that the height of the apex 66 of the ridge 62 may remain constant along the corrugated portion 60. However, it is also contemplated that the height of the apex 66 of the ridge 62 may vary along the corrugated portion 60. Similarly, it is contemplated that the depth of the nadir 68 on the groove 64 may remain constant along the corrugated portion 60. However, it is also contemplated that the depth of the nadir 68 of the groove 64 may vary along the corrugated portion 60.

[0028] In some examples, the width of the ridges 62 is the same width as the grooves 64. However, it is also contemplated that the width of the ridges 62 measured from the center of one groove 64 to the center of an adjacent groove 64 and the width of the grooves 64 measured from the apex 66 of one ridge 62 to the apex 66 of another ridge may differ from one another such that the width of the ridges 62 is greater than the width of the grooves 64 or such that the width of the grooves 64 is greater than the width of the ridges. It is further contemplated that the width of the ridges 62 may remain constant along the length of the corrugated portion 60. However, it is also contemplated that the width of the ridges 62 may vary along the corrugated portion 60. Similarly, it is contemplated that the width of the grooves 64 may remain constant along the length of the corrugated portion 60. However, it is also contemplated that the width of the grooves 64 may vary along the corrugated portion 60.

[0029] In some examples, the groove 64 has a width of about 0.5-1.5 mm. In other examples, the groove 64 has a width of about 0.8-1.3 mm. In yet other examples, the groove 64 has a width of about 0.9-1.1 mm. In one example, the groove 64 has a width of about 0.9 mm. In another example, the groove 64 has a width of about 1.1 mm. However, various other groove 64 widths are contemplated.

[0030] 6 and 7, the illustrated rocker insert 140 is similar to the rocker insert 40 described above with respect to the examples shown in FIGS. 3-5B, including, but not limited to, a rocker insert 140 including an upper wall 142, a lower wall 144, a side wall 146 extending between the upper wall 142 and the lower wall 144, and a corrugated portion 160. However, in the example shown in FIGS. 6 and 7, the rocker insert 140 is constructed of a plastic / metal hybrid material. In one example, the rocker insert 140 has a metal insert 170 that is overmolded with a plastic portion 172 to provide the final rocker insert 140. It is also contemplated that in other examples, the metal portion may be bonded to the plastic portion by various means including, for example, adhesives, fasteners, friction fit, and the like. The plastic / metal hybrid material provides improved strength over known rocker inserts while providing additional mass savings. The rocker insert 140 may also include an integral flange 174 having a height greater than a thickness of the upper wall 142 and / or the lower wall 144 for securing the rocker insert 140 to various other vehicle components, including, but not limited to, the sill inner 12 and the sill outer 14. The integral flange 174 may also be configured to allow the side wall 146 to be secured to the upper wall 142 and the lower wall 144. In one example, the flange is made integral with the metal insert 170, but may also be formed by the plastic material 172 or a separate flange. In some examples, the metal material is steel, although stainless steel and other metal materials are also contemplated. In some examples, the plastic material is a plastic polymer material, although other plastic materials are also contemplated.

[0031] Referring now to FIG. 8, in some examples, such as those described above, having a rocker insert 40, 140 with a corrugated portion 60 reduces mass by up to about 42%, while also reducing overall intrusion by about 22%, providing a lightweight yet sturdy rocker insert 40, 140.

[0032] The inner and outer sill panels 12, 14 and the rocker insert can be roll-formed from advanced high-strength steel having a tensile strength of over 1,000 MPA, such as about 1,500 MPA. The thickness of the metal sheet used to roll-form the center wall or membrane of the rocker insert can be about 1.2 mm, such as between 1.0 mm and 1.6 mm. Also, the steel sheet used for the rocker insert and the vehicle component panels can be galvanized to have a zinc coating that provides protection from corrosion. However, in some examples, the steel sheet of the rocker insert 40 can be non-galvanized, and in other examples, the steel sheet forming the vehicle component can be non-galvanized. In further examples, the metal sheet forming the rocker insert is an aluminum sheet. The length of the inner sill panel 12 is substantially equal to the length of the outer sill panel 14. In further implementations, the length of the inner sill panel 12 can be less than the length of the hollow interior space of the corresponding component, such as between 40% and 100%, between 30% and 90%, or between 30% and 60% of the length of the rocker insert. The sill inner 12 and sill outer 14 may be joined by welding, using fasteners, adhesives, or other joining methods. Joining the rocker insert 40 to one of the sill inner 12 and sill outer 14 may provide additional strength to the vehicle rocker assembly.

[0033] In a further example shown in Figures 9-12C, the illustrated rocker insert 240 is similar to the rocker insert 140 described above with respect to the example shown in Figures 6 and 7. However, as shown in Figures 12A-12C, the plastic portion 272 of the rocker insert includes an internal rib 276 extending between the upper and lower walls to support the hollow interior 250 of the rocker insert. The internal rib 276 shown in Figure 12A extends between vertically adjacent lowest points 268 of the groove such that the internal rib 276 is oriented substantially vertically within the vehicle. Additionally, as shown in Figure 12B, the internal rib 276 tapers in thickness as it extends from the outer wall 246 into the vehicle interior.

[0034] In yet another example shown in Figures 13-16D, the illustrated rocker insert 340 is similar to the rocker inserts 140 and 240 described above. However, as shown in Figures 16A-16D, the plastic portion 372 of the rocker insert 340 includes additional interior ribs 376a, 376b that provide a two-layer rib structure to the hollow interior 350 of the rocker insert. The outboard set of interior ribs 376a shown in Figure 16D has reinforcements that extend between the vertically adjacent lowest points 368 of the grooves, so that these reinforcements of the outboard set of interior ribs 376a are oriented substantially vertically within the vehicle. The outboard set of interior ribs 376a also includes horizontal reinforcements oriented to extend along the length of the rocker insert. The inboard set of interior ribs 376b are shown extending integrally into the vehicle from the vertical reinforcements of the outboard set of interior ribs 376a. However, the inboard set of interior ribs 376b do not span completely between the top and bottom walls so as to provide a gap between their inner edges 378, as shown in Figure 16C. Additionally, as shown in Figure 16B, the interior ribs similarly taper in thickness as they extend inwardly from the outer wall 346 of the rocker insert 340. Various alternative interior rib configurations and reinforcements are contemplated for other examples of rocker inserts.

[0035] As further shown in the rocker insert 340 depicted in Figures 13-16D, the metal plates partially forming the corrugated portions each include an outboard flange 380 that extends partially over the outer wall 346 of the rocker insert. The outboard flanges 380 may be formed by an integral section of the metal plate that is bent, pressed or otherwise formed to provide additional mass and reinforcement in the outboard area of ​​the rocker insert 340, which helps to support the corrugated portions of the metal plate in a generally horizontal orientation during a side impact to the vehicle.

[0036] 17-21, the illustrated rocker insert 440 is similar to the rocker insert 40 described above with respect to the example shown in FIGS. 3-5B, including, but not limited to, a rocker insert 440 including an upper wall 442, a lower wall 444, a side wall 446 extending between the upper wall 442 and the lower wall 444, and a corrugated portion 460. However, in the example shown in FIGS. 17-21, the rocker insert 440 may include an integral flange 474 having a height greater than the height of the side wall 444 for securing the rocker insert 440 to various other vehicle components, including, but not limited to, the sill inner 412 and the sill outer 414. The integral flange 474 may also be configured to allow the side wall 446 to be secured to the upper wall 442 and the lower wall 444. 17-21, the flange 474 is made integral with the rocker insert 440, however, it is contemplated that the flange 474 may be formed separately and later joined to the remainder of the rocker insert 440. In the illustrated example, the rocker insert 440 is a single, integral component, with the upper and lower walls 442, 444 extending away from the center near the flanged sidewall 446 and then bending downward to complete the flange 474. This allows the height of the flange 474 to be greater than the height of the opposing sidewall plus the height of the apex of the top and / or bottom of the corrugated portion 460. In one example, one or more of the upper and lower walls 442, 444 may extend generally perpendicular to the remainder of the upper and lower walls 442, 444 and bend away from the upper and lower walls 442, 444 before bending again in the opposite direction toward the upper and lower walls 442, 444 to form the flange wall. The bending or crimping process described provides a smooth surface large enough to mount the insert to the sill wall or other vehicle component.

[0037] In some examples, the corrugated portion 460 includes alternating ridges 462 and grooves 464. In the examples shown in FIGS. 17-21, the corrugated portion 460 has ridges 462 oriented to extend in a lateral direction of the vehicle. The lateral direction of the vehicle generally extends across the width dimension of the vehicle. In contrast, the longitudinal direction of the vehicle generally extends along the length dimension of the vehicle. In some examples, the peaks 466 of the ridges 462 may be disposed in a generally horizontal plane. The ridges 462 of the corrugated portion 460 are configured to be oriented to generally align with an expected lateral impact against the side of the vehicle to provide increased stiffness to the corresponding portion of the upper or lower wall 444 of the rocker insert 440. Additionally, the ridges 462 of the corrugated portion 460 extend at least partially between the sill wall portions of the sill inner 412 and the sill outer 414. In some examples, the corrugations 460 may be across the entire surface or may be located on only a portion of the surface. In the examples shown in Figures 17-21, the ridges 462 and grooves 464 are generally U-shaped, although various other shapes are contemplated. It is also contemplated that the ridges 462 and grooves 464 may be the same shape or different shapes from one another, as desired. It is further contemplated that the ridges 462 and / or grooves 464 may be a single repeating shape, alternating shapes, or any pattern, as desired.

[0038] In some examples, the height of the apex 466 of the ridge 462 is the same as the depth of the nadir 468 on the groove 464. However, it is also contemplated that the height of the apex 466 and the depth of the nadir 468 on the groove 464 may differ from one another, such that the height of the apex 466 of the ridge 462 is greater than the depth of the nadir on the groove 464 or vice versa. It is further contemplated that the height of the apex 466 of the ridge 462 may remain constant along the corrugated portion 460. However, it is also contemplated that the height of the apex 466 of the ridge 462 may vary along the corrugated portion 460. Similarly, it is contemplated that the depth of the nadir 468 on the groove 464 may remain constant along the corrugated portion 460. However, it is also contemplated that the depth of the nadir 468 of the groove 464 may vary along the corrugated portion 460.

[0039] In some examples, the width of the ridges 462 is the same width as the grooves 464. However, it is also contemplated that the width of the ridges 462 measured from the center of one groove 464 to the center of an adjacent groove 464 and the width of the grooves 464 measured from the apex 466 of one ridge 462 to the apex 466 of another ridge may differ from one another such that the width of the ridges 462 is greater than the width of the grooves 464 or such that the width of the grooves 464 is greater than the width of the ridges. It is further contemplated that the width of the ridges 462 may remain constant along the length of the corrugated portion 460. However, it is also contemplated that the width of the ridges 462 may vary along the corrugated portion 460. Similarly, it is contemplated that the width of the grooves 464 may remain constant along the length of the corrugated portion 460. However, it is also contemplated that the width of the grooves 464 may vary along the corrugated portion 460.

[0040] In some examples, the ridges 462 and / or grooves 464 are generally rounded such that the ridges and / or grooves have a generally U-shape. However, other shapes and configurations are contemplated, including, but not limited to, a V-shape or other angled shapes.

[0041] 17-21, the corrugated portions 460 are disposed on both the top and bottom surfaces of the upper and lower walls 442, 444, respectively, while the side walls 442 and opposing flange walls are smooth and / or generally flat surfaces. It is contemplated that the ridges 462 and / or grooves 464 of the upper and lower walls 442, 444 may extend slightly onto the side walls 446 or may extend completely around the side walls 446, as desired.

[0042] 22-27, the illustrated rocker insert 540 is similar to the rocker insert described above with respect to the example shown in FIGS. 3-5B, including but not limited to a rocker insert 540 including a top surface 552, a bottom surface 554, and a corrugated portion 560. However, in the example shown in FIGS. 22-27, the tubular member is comprised of a plurality of metal sheets 551 formed into tubular sections that are bonded together and to first and second side walls 546, 547. In the illustrated example, the tubular member includes seven separate plate segments 551 that are bent into a tubular structure having corrugated portions 560 on the top and bottom surfaces 552, 554. The plate segments 551 are comprised of original metal sheets that are bent, crimped, and secured into a tubular shape having top and bottom surfaces 552, 554 connected by a first side 553 and a second side 555 and defining a hollow interior. The hollow interior of the plate segment 551 extends between the first side wall 546 and the second side wall 547 of the rocker insert 540. Additionally, one or more of the first side 553 and the second side 555 are coupled to the first side 553 or the second side 555 of the second plate segment 551 to provide additional front-to-rear length. The first plate segment 551 and the second plate segment 551 may be welded or coupled in other manners, such as with fasteners or adhesives. It is also contemplated that one or more of the plate segments 551 may include one or more apertures disposed therein, if desired.

[0043] With further reference to the example shown in FIGS. 22-27, the corrugated portion 560 is also coupled to the first and second side walls 546, 547. The first and second side walls 546, 547 may be identical or mirror images of one another, or may have one or more different aspects from one another, as desired. In the example shown in FIGS. 22-27, the first side wall 546 is a generally planar wall that extends the entire length of the rocker insert 540. As shown, the first side wall 546 may include one or more apertures 561 disposed therethrough. The apertures 561 may be designed to reduce the weight of the rocker insert 540 and / or provide access for welding or other attachment. Additionally, although the example shown in FIGS. 22-27 illustrates the side wall 546 having a repeating pattern of apertures 561 disposed therein, any number, shape, and size of apertures may be present. It is further contemplated that one or more of the first and second side walls 546, 547 may be solid such that no apertures are present.

[0044] 22-27, the first and second side walls 546, 547 may have a height that is greater than the distance between the top surface 552 and the bottom surface 554 of the plate 551 such that the first and second side walls 546, 547 extend both above and below the top surface 552 and the bottom surface 554 of the plate 551. In one example, the plate 551 and the first and second side walls 546, 547 are coupled by welding, although it is contemplated that the plate 551 and the first and second side walls 546, 547 may be coupled by other methods, such as using fasteners, adhesives, etc.

[0045] In some examples, the corrugated portion 560 includes alternating ridges 562 and grooves 564. In the examples shown in FIGS. 22-27, the corrugated portion 560 has ridges 562 oriented to extend in a lateral direction of the vehicle. The lateral direction of the vehicle generally extends across the width dimension of the vehicle. In contrast, the longitudinal direction of the vehicle generally extends along the length dimension of the vehicle. In some examples, the peaks 566 of the ridges 562 may be disposed in a generally horizontal plane. The ridges 562 of the corrugated portion 560 are configured to be oriented to generally align with an expected lateral impact against the side of the vehicle to provide increased stiffness to corresponding portions of the upper or lower walls 544 of the rocker insert 540. Additionally, the ridges 562 of the corrugated portion 560 extend at least partially between the sill wall portions of the sill inner 512 and the sill outer 514. In some examples, the corrugations 560 may be across the entire surface or may be located on only a portion of the surface. In the examples shown in Figures 22-27, the ridges 562 and grooves 564 are generally U-shaped, although various other shapes are contemplated. It is also contemplated that the ridges 562 and grooves 564 may be the same shape or different shapes from one another, as desired. It is further contemplated that the ridges 562 and / or grooves 564 may be a single repeating shape, alternating shapes, or any pattern, as desired.

[0046] In some examples, the height of the apex 566 of the ridge 562 is the same as the depth of the nadir 568 on the groove. However, it is also contemplated that the height of the apex 566 and the depth of the nadir 568 on the groove 564 may differ from one another, such that the height of the apex 566 of the ridge 562 is greater than the depth of the nadir on the groove 564 or vice versa. It is further contemplated that the height of the apex 566 of the ridge 562 may remain constant along the corrugated portion 560. However, it is also contemplated that the height of the apex 566 of the ridge 562 may vary along the corrugated portion 560. Similarly, it is contemplated that the depth of the nadir 568 on the groove 564 may remain constant along the corrugated portion 560. However, it is also contemplated that the depth of the nadir 568 of the groove 564 may vary along the corrugated portion 560.

[0047] In some examples, the width of the ridges 562 is the same width as the grooves 564. However, it is also contemplated that the width of the ridges 562 measured from the center of one groove 564 to the center of an adjacent groove 564 and the width of the grooves 564 measured from the apex 566 of one ridge 562 to the apex 566 of another ridge may differ from one another such that the width of the ridges 562 is greater than the width of the grooves 564 or such that the width of the grooves 564 is greater than the width of the ridges. It is further contemplated that the width of the ridges 562 may remain constant along the length of the corrugated portion 560. However, it is also contemplated that the width of the ridges 562 may vary along the corrugated portion 560. Similarly, it is contemplated that the width of the grooves 564 may remain constant along the length of the corrugated portion 560. However, it is also contemplated that the width of the grooves 564 may vary along the corrugated portion 560.

[0048] In some examples, the ridges 562 and / or grooves 564 are generally rounded such that the ridges and / or grooves have a generally U-shape. However, other shapes and configurations are contemplated, including, but not limited to, a V-shape or other angled shapes.

[0049] It is also contemplated that the disclosed vehicle rocker assembly internal reinforcements may be incorporated into other types of structural beams, such as frames and structures of automobiles and marine vessels, buildings, storage tanks, furniture, and the like. With respect to vehicle applications, the vehicle components disclosed herein may be incorporated into a variety of applications of different structural components. The vehicle components may be designed to support and withstand different loading conditions, such as to support specific horizontal span or axial loading conditions. The vehicle components may also be designed to undergo various impact forces, such as for the illustrated rocker assemblies, pillar structures, and the like. The cross-sectional shape of the vehicle components, material type selection, and material thickness within the cross-sectional profile may be configured for desired load and performance characteristics, such as the weight of the particular application and vehicle component, beam load capacity, force deflection performance, and impact performance.

[0050] For purposes of this disclosure, the articles "a," "an," and "the" are intended to mean that there are one or more of the elements in the preceding description. The terms "comprising," "including," and "having" are intended to be inclusive and mean that there may be additional elements other than the listed elements. Furthermore, it is to be understood that references to "one embodiment" or "embodiments" of the present disclosure are not intended to be interpreted as excluding the existence of additional implementations that also incorporate the referenced features. Furthermore, the terms "first," "second," and the like, as used herein, do not denote order, quantity, or importance, but rather are used to describe an element from another element.

[0051] Any numerical values, percentages, ratios, or other values ​​described herein are intended to include that value and other values ​​that would be understood by a person skilled in the art to be "about" or "approximately" the described value, which are encompassed by implementations of the present disclosure. Thus, the described values ​​should be interpreted broadly enough to include values ​​that are at least sufficiently close to the described value to perform the desired function or achieve the desired result. For example, the terms "approximately," "about," and "substantially" can refer to an amount that is within 5%, within 1%, within 0.1%, and within 0.01% of the described amount.

[0052] Further, it should be understood that any directions or frames of reference in the preceding description are merely relative directions or movements. For example, the terms "up", "down", "right", "left", "rear", "front", "vertical", "horizontal", "inside", "outside" and their derivatives are intended to refer to the directions shown in FIG. 1. However, it is understood that various alternative orientations may be provided unless expressly specified to the contrary. It should also be understood that the specific apparatus and processes illustrated in the accompanying drawings and described herein are merely exemplary embodiments of the inventive concepts defined in the appended claims. Thus, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not considered limiting unless expressly recited in the claims.

[0053] Variations and modifications in the specifically described embodiments may be made 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. The present disclosure has been described in an illustrative manner, and it will be understood that the terms used are intended to be within the nature of the described words, rather than to be limiting. Many modifications and variations of the present disclosure are possible in light of the above teachings, and the present disclosure may be practiced otherwise than as specifically described.

Claims

1. Sil inner and a sill outer coupled to the sill inner to define an elongated hollow interior between the sill inner and the sill outer; a rocker insert disposed within the elongated hollow interior, the rocker insert including a corrugated portion having ridges oriented to extend in a lateral direction of the vehicle between the sill inner and the sill outer; 1. A vehicle locker assembly comprising:

2. The vehicle rocker assembly of claim 1 , wherein said corrugated portion comprises at least a portion of a metal sheet.

3. 3. The vehicle rocker assembly of claim 2, wherein the metal plate is supported by a plastic portion of the rocker insert configured to stabilize the metal plate laterally of the vehicle.

4. The vehicle rocker assembly of claim 3 , wherein said plastic portion is overmolded onto said metal plate.

5. 5. The vehicle rocker assembly of claim 1, wherein a cross-sectional shape of the corrugated portion along the longitudinal direction of the vehicle comprises a wave shape having a series of ridges that run parallel to one another.

6. The vehicle rocker assembly of any one of claims 1 to 4, wherein the ridge is a V-shaped ridge.

7. The vehicle rocker assembly of any one of claims 1 to 4, wherein the corrugated portion includes alternating ridges and grooves.

8. The vehicle rocker assembly of claim 5 , wherein said groove is a V-shaped groove.

9. 1. A vehicle rocker assembly comprising: a sill inner including a sill wall portion, an upper flange portion, and a lower flange portion; a sill outer including a sill wall portion, an upper flange portion, and a lower flange portion; the upper flange portion is joined to the upper flange portion of the sill outer and the lower flange portion of the sill inner is joined to the lower flange portion of the sill outer to define an elongated hollow interior between the sill inner and the sill wall portions of the sill outer; The vehicle rocker assembly further comprises: a rocker insert disposed within the elongated hollow interior, Upper wall, The lower wall, and a side wall extending between the upper wall and the lower wall, at least one of the upper wall or the lower wall including a corrugated portion having ridges oriented to extend laterally between the sill inner and the sill outer; Rocker inserts, 1. A vehicle locker assembly comprising:

10. 10. The vehicle rocker assembly of claim 9, wherein said ridges of said corrugated portion extend continuously between said sill wall portions of said sill inner and said sill outer.

11. 11. The vehicle rocker assembly of claim 9 or 10, wherein the sidewall is coupled with the sill inner or the sill outer to support the rocker insert within the elongated hollow interior.

12. The vehicle rocker assembly of any one of claims 9 to 11, wherein the rocker insert comprises a tubular member defined at least in part by the top wall, the bottom wall, and the side wall.

13. The vehicle rocker assembly of claim 12 , wherein the tubular member defines a hollow interior.

14. The vehicle rocker assembly of any one of claims 9 to 13, wherein the corrugated portions are disposed on both a top surface and a bottom surface of the top wall.

15. The vehicle rocker assembly of any one of claims 9 to 14, wherein the corrugated portions are disposed on both a top and a bottom surface of the lower wall.

16. the upper wall and the lower wall each include the corrugated portion; The vehicle rocker assembly of any one of claims 9 to 15, wherein a longitudinal cross-sectional shape of said upper wall and said lower wall includes a wave shape defining said corrugated portion.

17. The vehicle rocker assembly of any one of claims 9 to 16, wherein the corrugated portion includes a wave shape defined by alternating ridges and grooves.

18. 1. A rocker insert for a vehicle rocker assembly, the rocker insert comprising a sill inner including an upper flange and a lower flange, and a sill outer including an upper flange and a lower flange, the sill inner and the sill outer defining an elongated hollow interior therebetween, the rocker insert assembly being disposed within the elongated hollow interior; Upper wall, The lower wall, and a side wall extending between the upper wall and the lower wall, at least one of the upper wall or the lower wall including a corrugated portion having a ridge extending in a lateral direction of the vehicle between an inboard edge and an outboard edge of the respective upper wall or lower wall; Rocker insert.

19. 20. The rocker insert of claim 18, wherein the ridges of the corrugated portion are configured to extend between the sill inner and sill outer sill wall portions.

20. 20. The rocker insert of claim 18, wherein the sidewall is coupled to the sill inner or the sill outer for supporting the rocker insert within the elongated hollow interior.

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