Wave-shaped rocker insert

Abstract

The vehicle rocker assembly includes a sill outer and a sill inner that together define an elongated hollow interior. The vehicle rocker assembly also includes a rocker insert disposed within the elongated hollow interior. The rocker insert includes a stiffening member including at least one plate defining a corrugated structure and defining a leading edge, a trailing edge, a first side edge, and a second side edge opposite the first side edge. Further, the leading edge and the trailing edge are disposed at different locations along a length of the rocker insert. Further, a peak of the corrugated structure extends between the first side edge and the second side edge and is configured to carry a load path laterally between the inboard sidewall portion and the outboard sidewall portion.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of and priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 63 / 269,927, filed March 25, 2022, the disclosure of which is considered part of this application and is incorporated by reference in its entirety herein.

[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.

[0004] In electric and hybrid electric vehicles where a battery tray is 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, and it is commonly known to stiffen the vehicle sill assembly, for example by adding rocker inserts within the vehicle sill assembly. 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 structure having a sill outer and a sill inner defining an elongated hollow interior between an inboard wall portion of the sill inner and an outboard wall portion of the sill outer. The vehicle rocker assembly includes a rocker insert configured to be disposed within the elongated hollow interior, the rocker insert stiffening the rocker structure to reduce lateral intrusion as a result of a side impact to the vehicle, such as that performed in a side pole impact test. The rocker insert includes a stiffening member having a corrugated structure formed by at least one metal plate. The corrugations formed in the metal plate include alternating peaks and valleys disposed along a length of the rocker insert. The peaks and valleys of the corrugated structure extend between an inner edge and an outer edge of the metal plate to laterally carry a side impact load path between the sill inner and the sill outer.

[0006] Embodiments of the present disclosure may include one or more of the following optional features: In some embodiments, the crests and valleys of the corrugations each have a continuous cross-sectional shape extending laterally between the inner and outer edges of the metal plate. In additional examples, the cross-sectional shapes of the crests and valleys are mirror images across the vertical height of the stiffening member. In some examples, the crests of the waves may include a flat or planar area in the middle, which can be used to attach the stiffening member within the sill structure, such as via welding to a channel member or bracket, etc. In additional examples, the corrugations are composed of multiple plates bonded together in the vehicle longitudinal direction.

[0007] In some embodiments, the rocker insert includes a channel member having a top wall, a bottom wall, and side walls connecting along the top and bottom walls to define a channel region, such that the stiffening member is disposed along the channel region. In some examples, the top of the corrugation is attached to the top wall of the channel member. The channel member, in some examples, is coupled to a sill inner or sill outer to support the rocker insert within the elongated hollow interior. For example, the rocker insert may further include one or more wall members similarly attached along the stiffening member. In some embodiments, the rocker insert includes a first side wall and a second side wall disposed parallel to each other and coupled to inner and outer edges of the metal plate of the stiffening member.

[0008] In further embodiments, the corrugated structure includes a second plate defining a leading edge, a trailing edge, a first side edge, and a second side edge opposite the first side edge bonded to the first plate, such that the leading and trailing edges of the second plate are located at the same forward and aft locations as the leading and trailing edges of the second plate. In some examples, the peaks of the first plate are bonded to the valleys of the second plate.

[0009] In some embodiments, the thickness of the metal plate is defined between the upper and lower surfaces of the metal plate that extend between the inner and outer edges. In some examples, the upper surface faces upward of the sill structure, and the lower surface faces downward of the sill structure. For example, the thickness of the metal plate can be 0.08 to 4.0 mm, or 0.7 to 0.75 mm, or 0.05 to 0.5 mm.

[0010] In some embodiments, the rocker insert is disposed within a hollow interior of a sill assembly, the sill assembly including at least one of a sill outer having an outboard wall portion and a sill inner having an inboard wall portion that define the hollow interior. The rocker insert includes a stiffening member that defines a corrugated structure and includes at least one plate that defines a leading edge, a trailing edge, a first side edge, and a second side edge opposite the first side edge. The leading edge and the trailing edge are disposed at different locations along a length of the rocker insert. Further, a peak of the corrugated structure extends between the first side edge and the second side edge and is configured to carry a load path laterally between the inboard wall portion and the outboard wall portion.

[0011] In some embodiments, a vehicle rocker assembly includes a sill structure having an elongated hollow interior and a rocker insert disposed within the elongated hollow interior. The rocker insert includes a support member and a discontinuous stiffening member having a plurality of metal plates spaced apart along a length of the support member. Each of the plurality of metal plates includes a corrugated structure having at least one peak and at least one valley alternatingly disposed along a length of the metal plate. The peaks and valleys extend between an inner edge and an outer edge of the metal plate.

[0012] In a further embodiment, a vehicle battery tray includes a sidewall structure having an inboard wall portion and an outboard wall portion defining an elongated hollow interior therebetween. A stiffening insert is disposed within the elongated hollow interior. The stiffening insert includes a stiffening member having a metal plate having a length extending along at least a portion of the elongated hollow interior. The stiffening member includes a corrugated structure having alternating peaks and valleys disposed at spaced apart locations along the length of the metal plate. The peaks and valleys extend between inner and outer edges of the metal plate and are configured to carry a load path laterally between the inboard and outboard wall portions of the sidewall structure.

[0013] 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]

[0014] [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. [Diagram 5] FIG. 5 is a side view of the rocker insert shown in FIG. 4. [Figure 6] FIG. 5 is a top view of the rocker insert shown in FIG. 4. [Figure 7] FIG. 5 is an end view of the rocker insert shown in FIG. 4. [Figure 8A] FIG. 5 is an opposite side view of the rocker insert shown in FIG. 4. [Figure 8B] FIG. 8B is an enlarged view of the section shown in FIG. 8A. [Figure 9A] FIG. 5 is a perspective view of the corrugated structure of the rocker insert shown in FIG. [Figure 9B] FIG. 9B is an enlarged view of the section shown in FIG. 9A. [Figure 10] FIG. 13 is a perspective view of another example of a rocker insert. [Figure 11] FIG. 11 is an enlarged side view of the rocker insert shown in FIG. [Figure 12] FIG. 11 is an enlarged perspective view of the corrugated structure of the rocker insert shown in FIG. [Figure 13] FIG. 13 is a perspective view of another example of a rocker insert. [Figure 14] FIG. 14 is an enlarged side view of the rocker insert shown in FIG. 13. [Figure 15] FIG. 14 is an enlarged perspective view of the corrugated structure of the rocker insert shown in FIG. [Figure 16] FIG. 13 is a perspective view of another example of a rocker insert. [Figure 17] FIG. 17 is an enlarged side view of the rocker insert shown in FIG. 16. [Figure 18] FIG. 17 is a close-up perspective view of the corrugated structure of the rocker insert shown in FIG. [Figure 19] FIG. 13 is a perspective view of another example of a rocker insert. [Figure 20] FIG. 20 is an enlarged side view of the rocker insert shown in FIG. 19. [Figure 21] FIG. 20 is an enlarged perspective view of the corrugated structure of the rocker insert shown in FIG. 19. [Figure 22] FIG. 13 is a perspective view of another example of a rocker insert. [Diagram 23] FIG. 23 is an enlarged side view of the rocker insert shown in FIG. 22. [Figure 24] FIG. 23 is an enlarged perspective view of the corrugated structure of the rocker insert shown in FIG. [Diagram 25] FIG. 13 is a perspective view of another example of a rocker insert. [Figure 26] FIG. 26 is an enlarged side view of the rocker insert shown in FIG. 25. [Figure 27] FIG. 26 is an enlarged perspective view of the corrugated structure of the rocker insert shown in FIG. [Figure 28] FIG. 13 is a perspective view of another example of a rocker insert. [Figure 29] FIG. 29 is a top view of the rocker insert shown in FIG. 28. [Diagram 30] FIG. 29 is a side view of the rocker insert shown in FIG. 28. [Diagram 31] FIG. 29 is an end view of the rocker insert shown in FIG. [Diagram 32] FIG. 29 is an enlarged view of the rocker insert shown in FIG. 28. [Diagram 33] FIG. 29 is a perspective view of the rocker insert shown in FIG. 28 with the first side wall removed. [Diagram 34] FIG. 34 is a side view of the rocker insert shown in FIG. 33. [Diagram 35] FIG. 29 is a side view of another portion of the rocker insert shown in FIG. 28 with the first side wall removed. [Diagram 36]FIG. 13 is a perspective view of another example of a rocker insert. [Figure 37] FIG. 37 is a perspective view of the rocker insert shown in FIG. 36 with the first side wall removed. [Figure 38] FIG. 38 is a side view of the rocker insert shown in FIG. 37. [Figure 39] FIG. 37 is a cross-sectional view of the rocker insert shown in FIG. 36. [Diagram 40] FIG. 37 is an exploded view of the rocker insert shown in FIG. [Diagram 41] FIG. 13 is a perspective view of another example of a rocker insert. [Diagram 42] FIG. 42 is an enlarged side view of a section of the rocker insert shown in FIG. [Diagram 43] FIG. 42 is a perspective view of a section of the stiffening member of the rocker insert shown in FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] Like reference numbers refer to like parts throughout the drawings.

[0016] 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 102 as shown in FIG. 1 and FIG. 2. The vehicle frame 102 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 102 has various structural components, including B-pillars, hinge pillars, floor cross members, roof bows, and headers, 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 100 may be operated by a propulsion system that uses batteries, such as batteries or battery modules, that may be supported on a battery tray 104, 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.

[0017] The vehicle locker components include one or more sill panels, such as sill inner 12 and sill outer 14, attached together around an interior area 16, where the terms "inner" and "outer" refer to the inboard or inward facing and outboard or outward facing directions on the vehicle, as oriented in FIG. 1. As shown in FIGS. 2 and 3, an example vehicle locker assembly 10 includes a reinforcing insert disposed in the interior area 16 to form a multi-tubular locker structure. The rocker assembly 10 shown in FIG. 2 is positioned alongside an outer section of a battery tray 104, where a floor cross member is attached to the vehicle rocker assembly 10 to laterally straddle the battery tray 104. 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.

[0018] 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.

[0019] Additionally, the rocker inserts disclosed herein can be formed from one or more pieces of plate-like material to provide a structure having relatively high strength (against shear and axial loads) and low weight as 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.

[0020] Unless otherwise specified, it is generally understood that additional implementations of rocker components may have orientations opposite to those shown and described in the examples, such as a sill panel identified as a sill inner may be used as a sill outer and similarly a sill panel identified as a sill outer may be used as a sill inner. Additionally, in certain examples, the cross-sectional shapes of the inner and outer panels may vary along the rocker, such as by flaring outward at the ends.

[0021] 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 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 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. 3, the upper and lower flanges 18, 20, 22, 24 of each of the sill panels 12, 14 extend longitudinally and continuously along the edges of the rocker assembly 10. It is also contemplated that in some instances the flanges may be cut away in selected areas to facilitate attachment to a frame or other component, to reduce weight, etc.

[0022] As further shown in FIG. 3, the inner and outer sill panels 12, 14 are joined together to define an elongated hollow interior 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.

[0023] The first sill panel 12, i.e., the sill inner of the vehicle rocker assembly 10, has an inboard wall portion 26 that is substantially planar. The inboard wall portion 26 is integrally interconnected at its upper and lower ends with corner transitions to an upper wall portion 28 and a lower wall portion 30. The corner transitions are approximately 90 degrees between the inboard wall portion 26 and the upper and lower wall portions 28, 30. The corner transitions are also defined by longitudinal bends in the plate material forming the first sill panel 12, such as metal plate (e.g., advanced high strength steel plate or aluminum plate). Similarly, the upper and lower wall portions 28, 30 each have approximately 90 degree corner transitions with the upper and lower flanges 18, 20, respectively. The corner transitions are also defined by longitudinal bends in the plate material of the first sill panel 12, such as formed by a roll forming process. As also shown in Figure 3, the upper and lower flanges 18, 20 are substantially planar and oriented in parallel alignment with the planar extent of the interior sidewall portion 26. The upper and lower wall portions 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 between approximately 40 and 120 degrees, between 70 and 100 degrees, between 80 and 95 degrees, or between 82 and 92 degrees.

[0024] As also shown in FIG. 3, the second sill panel 14 or sill outer of the vehicle rocker assembly 10 is substantially planar and has an outboard wall portion 32 integrally interconnected at respective upper and lower ends with an upper wall portion 34 and a lower wall portion 36. An approximately 80 degree corner transition between the outboard wall portion 32 and the upper and lower wall portions 34, 36 is defined by a longitudinal bend in the plate material forming the second sill panel 14. The plate material may be the same or different than the first sill panel 12 and may include a metal plate such as a high strength steel plate or an aluminum plate. Similarly, the upper wall portion 34 also has a corner transition to the upper flange 22 and the lower wall portion 36 also has a corner transition to the lower flange 24, each also defined by a longitudinal bend in the plate material of the second sill panel 14. Again, the corner transitions between the upper and lower wall portions 34, 36 and the upper and lower flanges 22, 24 and the exterior side wall portion 32 may have greater or lesser angular transitions than shown in FIG. 4, such as between about 40 degrees and 120 degrees, between 70 degrees and 100 degrees, between 80 degrees and 95 degrees, or between 82 degrees and 92 degrees.

[0025] 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 outboard wall portion 32. The upper and lower wall portions 34, 36 of the second sill panel 14 are also substantially planar, but slightly angled from being perpendicular to the outboard wall portion 32 and the flanges 22, 24. With the flanges 18, 20, 22, 24 of the panels 12, 14 attached together, their walls define a substantially hexagonal cross-sectional shape, although it is understood that additional examples of the rocker insert may have a variety of alternative cross-sectional shapes (e.g., substantially rectangular shapes) and different wall configurations (e.g., portions of the inboard or outboard wall portions that are not vertically oriented) for corresponding vehicle designs. It is also contemplated that in other examples, the sill outer and sill inner may each include different configurations, including, but not limited to, the sill outer having inwardly or outwardly protruding stiffening rib portions configured to provide additional stiffness and side impact support.

[0026] 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 assembly 10 includes a stiffening member 42 defining a corrugated structure 44. The stiffening member 42 includes at least one plate 46 defining a leading edge 48, a trailing edge 50, a first side edge 52, and a second side edge 54 opposite the first side edge 52 (Figure 9B). As further shown in Figure 9B, the first and second side edges 52, 54 are disposed parallel to one another along the length of the rocker insert 40. In one example, the leading edge 48 and the trailing edge 50 are disposed at different locations along the length of the rocker insert 40.

[0027] The at least one plate 46 may be formed from a flat metal sheet 46, such as coiled steel or aluminum, by pressing, roll forming, or other bending into a desired shape. It is also contemplated that the at least one plate 46 may be constructed from another material having the desired strength requirements and / or from non-coiled steel or aluminum. In some examples, such as shown in FIGS. 3 and 4, the elongated metal plate forming the corrugated structure of the stiffening member 42 is a single plate that extends along the length of the elongated hollow interior of the rocker assembly 10. The single plate forming the stiffening member 42 may be press formed, such as by progressive stamping, which repeats alternating peaks and valleys along the length of the rocker insert. In additional examples, the metal plate may be roll formed, such as transversely to the vehicle, to form a consistent cross-sectional shape that is cut into multiple plate segments to be repeated along the rocker insert, such as those shown in FIGS. 41-43.

[0028] In some examples, the stiffening member 42 may include a plurality of plates 46 coupled to one another in the vehicle longitudinal direction, each defining a leading edge 48, a trailing edge 50, a first side edge 52, and a second side edge 54 opposite the first side edge 52. Furthermore, the leading edge 48 and the trailing edge 50 of each of the plurality of plates 46 are disposed at different positions along the length of the rocker insert 40. Furthermore, the corrugated structure 44 includes a second plate 46 defining a leading edge 48, a trailing edge 50, a first side edge 52, and a second side edge 54 opposite the first side edge 52 coupled to the first plate 46 such that the leading edge 48 and the trailing edge 50 of the second plate 46 are disposed at the same forward and rearward positions as the leading edge 48 and the trailing edge 50 of the second plate 46. In one example, the crest 62 of the first plate is joined to the crest 62 of the second plate, although various other configurations are contemplated, such as joining a crest to an adjacent valley or trough, such as at a lap joint at the vertical center of the stiffening member corrugations. In one example, the first plate 46 and the second plate 46 are joined by welding, although various other joining methods are contemplated, including but not limited to the use of fasteners and / or adhesives.

[0029] Referring again to the example shown in Figures 3 and 4, the cross-sectional shape of the corrugated structure 44 includes a wave-like shape having a series of peaks or valleys that extend parallel to one another and laterally on the stiffener member relative to the longitudinal extent of the rocker assembly 10. The corrugated structure 44 includes a peak 62 defined as the highest point or portion of the corrugated structure 44 and may include a perimeter thereof. The corrugated structure 44 also includes a valley or trough 64 defined as the lowest point or portion of the corrugated structure 44 and may include a perimeter thereof. Thus, for purposes of this disclosure, a corrugated structure includes at least two peaks or at least two valleys, such as to have a full wavelength. The corrugated structure 44 is further defined by the peaks 62 alternating with the penetrations 64. In one example, the peaks 62 of the corrugated structure 44 extend between the first side edge 52 and the second side edge 54 and are configured to carry a load path laterally between the interior sidewall portion and the exterior sidewall portion. In other words, the peaks 62 of the corrugations 44, if included, extend at least partially between the sill inner and outer sill edges. As shown in the example illustrated in Figures 3 and 4, the valleys 64 of the corrugations 44 also extend between the first and second side edges 52, 54 and are configured to carry a load path laterally between the inboard and outboard wall portions.

[0030] A lateral vehicle direction generally extends across the width dimension of the vehicle. In contrast, a longitudinal vehicle direction generally extends along the length dimension of the vehicle. In some examples, the peaks 62 may be disposed in a generally horizontal plane. The peaks 62 and valleys 64 of the corrugated structure 44 are configured to be oriented to be generally aligned with an expected lateral impact against the side of the vehicle, thereby providing increased stiffness to the corresponding portion of the upper or lower wall F of the rocker insert 40. Additionally, the peaks 62 and valleys 64 of the corrugated structure 44 extend at least partially between the sill wall portions of the sill inner 12 and sill outer 14. In some examples, the corrugated structure 44 may extend over the entire surface or may be disposed on only a portion of the surface. The peaks 62 and valleys 64 may be of any shape and profile desired, including, but not limited to, the peaks and valleys 62, 64 being V-shaped or U-shaped. The peaks 62 and valleys 64 may also include portions beyond the highest or lowest points on the plate, such that such portions may include sections of the plate that include formations on the upper or lower surface, such as laterally extending channels, and the like. It is also contemplated that the peaks 62 and valleys 64 may be the same shape, such as mirror image shapes across the vertical center of the corrugations, or may be different shapes from one another, such as those shown in Figures 22-27. It is further contemplated that the peaks 62 and / or valleys 64 may be a single repeating shape, alternating shapes, or any pattern desired.

[0031] In some examples, the height of the crests 62 is the same as the depth of the lowest point on the valleys 64. However, it is also contemplated that the height of the crests 62 and the depth of the lowest point on the valleys 64 may differ from one another, such that the height of the crests 62 is greater than the depth of the valleys 64 or vice versa. Further, the height of the crests 62 may remain constant along the corrugated structure 44, as shown in Figures 3-9B. However, it is also contemplated that the height of the crests 62 may vary along the corrugated structure 44. Similarly, the depth of the valleys 64 may remain constant along the corrugated structure 44, as shown in Figures 3-9B. However, it is also contemplated that the depth of the valleys 64 may vary along the corrugated structure 44.

[0032] In some examples, the width of the crests 62 is the same width as the valleys 64. However, it is also contemplated that the width of the crests 62 measured from the center of one valley 64 to the center of an adjacent valley 64 and the width of the valleys 64 measured from one crest 62 to another crest may differ from one another such that the width of the crests 62 is greater than the width of the valleys 64 or such that the width of the valleys 64 is greater than the width of the crests. It is further contemplated that the width of the crests 62 may remain constant along the length of the corrugated structure 44. However, it is also contemplated that the width of the crests 62 may vary along the corrugated structure 44. Similarly, it is contemplated that the width of the valleys 64 may remain constant along the length of the corrugated structure 44. However, it is also contemplated that the width of the valleys 64 may vary along the corrugated structure 44.

[0033] In the example shown in Figures 3 and 4, the cross-sectional shape begins with a crest 62, which is a generally flat surface. The corrugated portion then changes to an angled portion 68 that extends downward at an angle before reaching a valley 64, which is another generally flat surface. Another angled portion 68 extends upward from the flat surface of the valley 64 to a second crest. In the example shown, the angled portion 68 extends at an angle of approximately 45 degrees, although other angles from 15 to 105 degrees may be completed. The angled portion 68 provides a shape such that the distance between the first valley 64 and the second valley 64 is greater than the length of the crest. Similarly, the distance between the first crest 62 and the second crest 62 is greater than the length of the valley. This shape is then repeated in a pattern throughout the length, as shown in the example shown in Figures 3 and 4. However, various other shapes are contemplated. Additionally, the angled portion 68 between the valleys 64 and the crests 62 may include one or more reinforcing ribs 70 configured to provide additional strength to the corrugated portion. In the example shown, the transition between the angled portion 68 and the crests 62 / valleys 64 and near the reinforcing ribs 70 is a curved angle, although various other configurations are contemplated, including more acute transitions.

[0034] The rocker insert 40 may also be a support or channel member including at least two of a top wall 80, a bottom wall 82, a first side wall 84, and a second side wall 86. In the example shown in Figures 3 and 4, the rocker insert 40 includes a channel member having a top wall 80, a bottom wall 82 disposed generally parallel to the top wall 80, and a first side wall 84 extending between the top wall 80 and the bottom wall 82, such as to form a C-shaped channel. In one example, the top wall 80 and the bottom wall 82 are generally flat parallel extending surfaces, although various other embodiments are contemplated including corrugations disposed on one or more of the top wall 80 and the bottom wall 82. In the example shown, both the top wall 80 and the bottom wall 82 have flange portions 88 extending at an angle from the top wall 80 and the bottom wall 82. The angle between the flange and the top or bottom wall 82 may be approximately 90 degrees, although various other angles are contemplated including, but not limited to, angles ranging from 25 to 125 degrees. The flange portion 88 is configured to allow the rocker insert 40 to be coupled to another vehicle component, such as a sill inner, a sill outer, or another vehicle component.

[0035] Further, in the example shown, the side walls curve outward from both the top and bottom surfaces, then curve inward toward the corrugated portion and meet at a recess 90. In some examples, the recess 90 is curved to have a generally U-shape, although a variety of other shapes are contemplated. In some examples, one or more of the top wall 80 or bottom wall 82 may include a notch for accommodating other vehicle components without departing from the spirit of the invention.

[0036] With further reference to the example shown in Figures 3 and 4, it is contemplated that one of the side walls and / or flange portions 88 of the top and bottom walls 82 may be coupled to one of the inner or outer sill to support the rocker insert 40 within the elongated hollow interior 16. Again, this coupling may be by welding, although other coupling methods are contemplated, including but not limited to the use of fasteners or adhesives. In one example, the side walls are coupled to the inner sill. In another example, the side walls are coupled to the outer sill. In another example, the flange portions 88 of the top and / or bottom walls 82 are coupled to the outer sill. In another example, the flange portions 88 of the top and / or bottom walls 82 are coupled to the inner sill.

[0037] It is also contemplated that the peaks 62 and valleys 64 of the corrugations may be bonded to the top and bottom walls 80, 82, respectively, as discussed above. Typically, this bonding is achieved by welding, although other processes are contemplated, including, but not limited to, fasteners or adhesives.

[0038] The stiffening members and the support or channel members can be formed of a metal plate material, such as high strength steel plate. The thickness of the metal plate is defined between an upper surface and a lower surface of the metal plate that extend between an inner edge and an outer edge. In some examples, the upper surface faces upward in the sill structure and the lower surface faces downward in the sill structure. For example, the thickness of the metal plate can be 0.08-0.4 mm, or 0.07 mm-0.2 mm, or 0.08-0.4 mm, or 0.08-0.18 mm, or 0.12-0.16 mm, or 0.08-4.0 mm, or 0.01-0.75 mm, or 0.05-0.5 mm.

[0039] 1-9B, including, but not limited to, one or more of a sill outer 114 or sill inner 112, a rocker insert 140 including a top wall 180, a bottom wall 182, and a side wall 184, and a stiffening member 142 defining a corrugated structure 144 including a plate 146 having a leading edge 148 and a trailing edge 150 disposed at different positions along the length of the rocker insert 140. However, as shown in the example shown in Figures 10-12, the angled portion 168 of the corrugated structure 144 extends at a smaller angle than in the example shown in Figures 1-9B. More specifically, the angled portion 168 of the corrugated structure 144 extends at an angle slightly greater than 90 degrees, for example, an angle in the range of 95-105 degrees, such that the distance between the first peaks 162 and the second peaks 162 is just slightly greater than the width of the valleys 164. Similarly, as best shown in FIG. 11 , the distance between the first valleys 164 and the second valleys 164 is just slightly greater than the width of the peaks 162.

[0040] 13-15, a rocker assembly 210 includes similar features as those discussed above with respect to the rocker assembly 10 shown in FIGS. 1-9B, including, but not limited to, one or more sill outer 214 or sill inner 212, a rocker insert 240 including a top wall 280, a bottom wall 282, and a side wall 284, and a stiffening member 242 defining a corrugated structure 244 including a plate 246 having a leading edge 248 and a trailing edge 250 disposed at different positions along the length of the rocker insert 240. However, as shown in the example shown in FIGS. 10-12, the angled portion 268 of the corrugated structure 244 extends at an angle of approximately 90 degrees before reaching the reinforcing rib 270, and then continues to extend approximately perpendicular to the peaks 262 and valleys 264. As such, the distance between the first peak 262 and the second peak 262 is approximately equal to the width of the valley 264. Similarly, as best shown in FIG. 11, the distance between the first valley 264 and the second valley 264 is approximately equal to the width of the peak 262 .

[0041] 16-18, a rocker assembly 310 includes similar features as those discussed above with respect to rocker assembly 10 shown in FIGS. 1-9B, including, but not limited to, one or more sill outer 314 or sill inner 312, a rocker insert 340 including a top wall 380, a bottom wall 382, ​​and a side wall 384, and a stiffening member 342 defining a corrugated structure 344 including a plate 346 having a leading edge 348 and a trailing edge 350 disposed at different positions along the length of the rocker insert 340. However, as shown in the example shown in FIGS. 10-12, an angled portion 368 of the corrugated structure 344 extends from a crest 362 at a generally 90 degree angle before reaching a reinforcing rib 370, and then continues inwardly from the reinforcing rib 370 and extends at an angle toward the crest 362. Thus, the distance between the first crest 362 and the second crest 362 is less than the width of the valley 364. Similarly, as best seen in FIG. 11, the distance between the first valley 364 and the second valley 364 is less than the width of the peak 362 .

[0042] 19-22, a rocker assembly 410 includes similar features as those described above with respect to the rocker assembly 10 shown in FIGS. 1-9B, including, but not limited to, one or more sill outers 414 or sill inners 412, a rocker insert 440 including a top wall 480, a bottom wall 482, and a side wall 484, and a stiffening member 442 defining a corrugated structure 444 including a plate 446 having a leading edge 448 and a trailing edge 450 disposed at different positions along the length of the rocker insert 440. Additionally, the corrugated structure 444 is similar in shape to that described with respect to the example shown in FIGS. 1-9B. However, the stiffening member 42 includes a second corrugated structure having an identical shape disposed therein. In this example, the top 462 of the first corrugated structure 444 is bonded to the top wall 80 of the stiffening member 444. Additionally, the valleys 464 of the second corrugations 444 are bonded to the bottom wall 482 of the stiffening member 442. As additionally shown in Figures 19-24, the reinforcing ribs 470 can have a more angular shape rather than the more curved shape shown in the example of Figures 1-9B. It is further contemplated that the reinforcing ribs 470 can be positioned at an angle closer to the peaks 462 or closer to the valleys 464, as desired.

[0043] 22-24, a rocker assembly 510 includes similar features as those described above with respect to the rocker assembly 10 shown in FIGS. 1-9B, including, but not limited to, one or more sill outers 554 or sill inners 552, a rocker insert 540 including a top wall 580, a bottom wall 582, and a side wall 584, and a stiffening member 542 defining a corrugated structure 544 including a plate 546 having a leading edge 548 and a trailing edge 550 disposed at different positions along the length of the rocker insert 540. However, as shown in the example shown in FIGS. 22-24, the angled portion 568 of the corrugated structure 544 extends at a larger angle than shown in FIGS. 1-9B. The angle of extension is greater than 90 degrees and can range from 95 to 130 degrees. Furthermore, upon reaching the reinforcing rib 570, the angled portion 568 extends back toward the valley 564 at a similar angle. As such, the distance between the first peaks 562 and the second peaks 562 is approximately equal to the width of the valleys 564. Similarly, as best shown in FIG. 23, the distance between the first valleys 564 and the second valleys 564 is approximately equal to the width of the peaks 562.

[0044] 25-27, a rocker assembly 610 includes similar features as those discussed above with respect to the rocker assembly 10 shown in FIGS. 1-9B, including, but not limited to, one or more sill outers 664 or sill inners 662, a rocker insert 640 including a top wall 680, a bottom wall 682, and a side wall 684, and a stiffening member 642 defining a corrugated structure 644 including a plate 646 having a leading edge 648 and a trailing edge 650 disposed at different positions along the length of the rocker insert 640. Additionally, the example shown in FIGS. 25-27 has an angle of extension of the angled portion similar to the example shown in FIGS. 22-24. However, as shown in the example shown in FIGS. 25-27, the angled portion 668 of the corrugated structure 644 does not include a reinforcing rib, but instead has a smooth curve extending from the peak 662 to the valley 664. In this manner, the distance between the first peaks 662 and the second peaks 662 is approximately equal to the width of the valleys 664. Similarly, as best shown in FIG. 23, the distance between the first valleys 664 and the second valleys 664 is approximately equal to the width of the peaks 662.

[0045] 28-35, a rocker assembly 710 includes similar features as those discussed above with respect to the rocker assembly 10 shown in FIGS. 1-9B, including, but not limited to, one or more sill outer 714 or sill inner 712 and a rocker insert 740 including a stiffening member 742 defining a corrugated structure 744 including a plate 746 having a leading edge 748 and a trailing edge 750 disposed at different positions along the length of the rocker insert 740. However, in the example shown in FIGS. 28-35, the corrugated structure 744 is comprised of a first plate 744 and a second plate 744 that are joined on top of each other. In the example shown, the first plate 744 and the second plate 744 are joined such that the valleys 764 of the first plate 744 are joined to the peaks 762 of the second plate 744 to form a generally hexagonal repeating structure. As discussed above, the bonding is typically accomplished by welding, although various other bonding methods are contemplated, including but not limited to the use of fasteners and / or adhesives. Additionally, as shown in FIGS. 28-35, the corrugated structure 744 is bonded to a first sidewall 784 and a second sidewall 786. Again, the bonding is typically accomplished by welding, although various other bonding methods are contemplated, including but not limited to the use of fasteners and / or adhesives. In the illustrated example, the first sidewall 784 and the second sidewall 786 are generally coplanar walls that extend the length of the rocker insert 740. Additionally, the first and second sidewalls 784, 786 may include at least one aperture 792. The aperture 792 may be a repeating aperture as shown in FIGS. 28-35, may be a single aperture, or may be another arrangement of apertures. Additionally, other sidewall shapes and configurations are contemplated. In one example, rocker insert 740 is a plastic / metal hybrid such that one or more components of the corrugations or sidewalls are constructed from a plastic material and one or more of the components of the corrugations or sill walls are constructed from a metal material. In the example shown, it is contemplated that corrugations 714 may include a core constructed from a plastic configured to provide additional strength to rocker insert 740.

[0046] 36-40, a rocker assembly 810 includes similar features as those discussed above with respect to rocker assembly 10 shown in FIGS. 1-9B, including, but not limited to, one or more of a sill outer 814 or sill inner 812 and a rocker insert 840 including a stiffening member 842 defining a corrugated structure 844 including a plate 846 having a leading edge 848 and a trailing edge 850 disposed at different positions along the length of the rocker insert 840. However, in the example shown in FIGS. 36-40, the stiffening member is configured to replace one or more of the sill outer 814 or sill inner 812. The stiffening member 842 includes a first sidewall 884 and a second sidewall 886 configured to be joined together to form a hollow interior within which the corrugated structure 844 is disposed. As best shown in FIG. 39, the first side wall 884 and the second side wall 886 each have flange portions 888 at the top and bottom that are configured to be joined together in a manner similar to conventional sill outer and sill inner walls, i.e., by bonding a top flange portion of the first side wall 884 to a top flange portion of the second side wall 886 and bonding a bottom flange portion of the first side wall 884 to a bottom flange portion of the second side wall 886. The stiffening member 842 has a shape similar to the sill outer 814 and the sill inner 812, allowing one or more of the sill outer 814 and the sill inner 812 to be replaced by the stiffening member 842. In other words, the stiffening member 842 can be directly bonded to other vehicle components that are typically bonded to the sill inner 812 or the sill outer 814. In the illustrated example, the first side wall 884 is similar to the side wall 884 described above with respect to FIGS. 1-9B, including having a recess 890. 36-40 are angular rather than curved, although various configurations are contemplated. Additionally, second sidewall 886 also includes a recess, but the recess on second sidewall 886 extends from the recess to the top surface of second sidewall 886. Other locations and configurations of the recess are also contemplated.It is further contemplated that any of the corrugations 44 , 144 , 244 , 344 , 444 , 544 , 644 , 744 described herein may be disposed within a similar stiffening member 842 .

[0047] 41-43, a rocker insert 940 and corresponding rocker assembly includes similar features as those described above with respect to the rocker assemblies shown in FIGS. 1-9B, including, but not limited to, one or more sill outers or sill inners that define an elongated hollow interior for receiving the rocker insert. The rocker insert 940 includes a channel or support member having a top wall 980, a bottom wall 982, and side walls 984, along with stiffening members 942 that define a corrugated structure. The stiffening members 942 include multiple metal plates 946a, 946b (FIG. 42) with a leading edge of one plate 946a attached to a trailing edge of an adjacent plate 946b. Specifically, each metal plate shown includes three peaks 962 and two valleys 964, with the peaks 962 of adjacent corrugated plates attached in a lap joint configuration. The lap joints of adjacent plate portions are attached by welding, such as via spot welding, laser welding, or the like. It is also contemplated that adjacent plates may include different shapes, materials, thicknesses, or other characteristics such that the reinforcing insert formed by the multiple plates may have variable strength along its length, such that, for example, certain sections of the length may be tailored for different impact load paths or crush requirements. It is also contemplated that adjacent plates may include a space between adjacent leading and trailing ends to provide a section of the rocker insert having a lower stiffness in that space. In such an example, the rocker insert includes discontinuous stiffening members along the length of the support member. Additionally, the example shown in Figures 41-43 has a similar angle of extension of the angled portion 968 as the example shown in Figures 8A-9B, and a similar reinforcing rib 970 as shown in Figures 8A-9B.

[0048] 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.

[0049] For purposes of this disclosure, the term "coupled" (in all its forms, coupled, bonded, etc.) generally means that two components are joined directly or indirectly to one another. Such joining may be essentially stationary or movable, may be achieved by the two components and any additional intermediate members, or may be achieved by being integrally formed with one another or with the two components as a single unit, and may be by fixed attachment or by interfacial or abutting contact, unless otherwise stated.

[0050] Also, 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 should 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. a sill structure having an inboard wall portion and an outboard wall portion defining an elongated hollow interior therebetween; A vehicle rocker assembly including a rocker insert disposed within the elongated hollow interior, The rocker insert is a stiffening member having a metal plate having a length extending along at least a portion of the elongated hollow interior; the stiffening member includes a corrugated structure having alternating peaks and valleys spaced apart along the length of the metal plate; the peaks and valleys extend between inner and outer edges of the metal plate and are configured to carry a load path laterally between the interior sidewall portion and the exterior sidewall portion of the sill structure. Vehicle locker assembly.

2. a length of the metal plate extends between a leading edge and a trailing edge of the metal plate; The vehicle rocker assembly of claim 1 , wherein said leading and trailing edges are disposed at spaced locations along said elongated hollow interior of said sill structure.

3. 2. The vehicle rocker assembly of claim 1, wherein a plate thickness of the metal plate is defined between an upper surface and a lower surface of the metal plate extending between the inner edge and the outer edge, the upper surface facing upward at the sill structure, and the lower surface facing downward at the sill structure.

4. The vehicle rocker assembly of claim 1 , wherein the peaks and valleys of the corrugations include a consistent cross-sectional shape extending laterally between the inner and outer edges of the metal sheet.

5. The vehicle rocker assembly of claim 4 , wherein the cross-sectional shape of said peaks is a mirror image of the cross-sectional shape of said valleys.

6. The vehicle rocker assembly of claim 4 , wherein a cross-sectional shape of said apex of said corrugated structure includes a mid-plane section.

7. the rocker insert further includes a channel member having a top wall, a bottom wall, and side walls connecting along the top and bottom walls to define a channel region; The vehicle rocker assembly of claim 6 , wherein said stiffening member is disposed along said channel area with said mid-planar section of said top attached to said top wall of said channel member.

8. The vehicle rocker assembly of claim 1 , wherein said stiffening member includes a second corrugated plate extending along said elongated hollow interior.

9. The vehicle rocker assembly of claim 8 , wherein a front end of said second corrugated plate is attached to a rear end of said metal plate.

10. 2. The vehicle rocker assembly of claim 1, wherein at least one of the inner or outer edges of the metal plate is bonded to a respective interior or exterior sidewall portion of the sill structure.

11. The vehicle rocker assembly of claim 1 , wherein the inner and outer edges of the metal plate extend parallel to one another along a length of the metal plate.

12. 1. A rocker insert configured to be disposed along a hollow interior of a vehicle sill structure, comprising: the rocker insert includes a stiffening member including a metal plate defining a corrugation along a length of the metal plate; the corrugations include alternating peaks and valleys at spaced locations along the length of the metal plate; the peaks and valleys of the corrugations extend between inner and outer edges of the metal plate; A plate thickness of the metal plate is defined between an upper surface and a lower surface of the metal plate extending between the inner edge portion and the outer edge portion, such that the upper surface is configured to face upward in the vehicle sill structure and the lower surface is configured to face downward in the vehicle sill structure. Rocker insert.

13. The rocker insert according to claim 12, wherein the metal plate has a thickness of 0.08 mm to 4.0 mm.

14. The rocker insert of claim 12 , wherein the metal plate includes a leading edge and a trailing edge and is disposed at opposite ends of the stiffening member.

15. The rocker insert of claim 14 , wherein the stiffening member includes a second corrugated plate having a forward end attached to the aft end of the metal plate.

16. The rocker insert of claim 12 , wherein the peaks and valleys of the corrugations include a consistent cross-sectional shape extending laterally between the inner and outer edges of the metal sheet.

17. The rocker insert of claim 12 , wherein the cross-sectional shape of the peaks is a mirror image of the cross-sectional shape of the valleys when transverse to the vertical center of the stiffening member.

18. 13. The rocker insert of claim 12, further comprising a channel member having a top wall, a bottom wall, and side walls connecting along said top and bottom walls to define a channel area, said stiffening member being disposed along said channel area with said top portion attached to said top wall of said channel member.

19. a sill structure having an inboard wall portion and an outboard wall portion defining an elongated hollow interior therebetween; A vehicle rocker assembly including a rocker insert disposed within the elongated hollow interior, The rocker insert is a stiffening member including a metal plate having a length extending along at least a portion of the elongated hollow interior; a support member attached along a length of the stiffening member; the stiffening member includes a corrugated structure having alternating peaks and valleys at spaced locations along the length of the metal plate; the peaks and valleys extend between inner and outer edges of the metal plate and are configured to carry a load path laterally between the interior and exterior sidewall portions of the sill structure. Vehicle locker assembly.

20. 20. The vehicle rocker assembly of claim 19, wherein a thickness of the metal plate is defined between an upper surface and a lower surface of the metal plate extending between the inner edge and the outer edge, the upper surface facing upward at the sill structure, and the lower surface facing downward at the sill structure.

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