VEHICLE BEAM ASSEMBLY WITH COOPERATING STIFFENING MEMBER - Patent application

Abstract

The vehicle rocker assembly (10) includes a sill outer panel (14) and a sill inner panel (12) to define an elongated hollow interior (16). The vehicle rocker assembly also includes a rocker insert (40) disposed within the hollow interior. The rocker insert includes a first stiffening member (41) having a top wall (80), a bottom wall (82), and a side wall (84). The rocker insert also includes a second stiffening member (42) including a plurality of wall sections, each of the wall sections including an upper portion that engages the top wall and a lower portion that engages the bottom wall at a location spaced along the length of the rocker insert from the upper portion. The top and bottom walls of the first stiffening member are configured to be supported by the second stiffening member upon an inboard lateral impact force to enhance the lateral bending strength of the rocker insert.

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 / 363,785, filed April 28, 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 structural members and beams, and more particularly to vehicle components for use as structural and reinforcing beams, for example, in rocker assemblies, battery trays, and other vehicle frame 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 structural component, such as a rocker component, that includes a beam assembly having at least two types of stiffening members attached together to provide the component with high bending strength and crush resistance. In some examples, the beam assembly can be a vehicle rocker assembly that includes a stiffening member disposed within a hollow interior of the rocker assembly. The stiffening member has a top wall, a bottom wall, and a side wall, for example forming a C-shaped cross section. The rocker assembly also includes a second stiffening member having a plurality of wall sections, each of which includes an upper portion that engages with the top wall of the first stiffening member and a lower portion that engages with the bottom wall of the first stiffening member at a location spaced along the length of the rocker assembly from the upper portion. The two types of stiffening members function cooperatively in side impact energy management, for example, the top and bottom walls of the first stiffening member are supported in a generally planar parallel alignment by the second stiffening member upon an inboard lateral impact force to enhance the lateral bending strength of the rocker insert. The wall sections of the second stiffening member are also configured to align with lateral impact loads to provide high crush resistance and stiffness to the rocker section. The combined properties of the cooperating stiffening members provide enhanced resistance to intrusion as a result of a side impact along the length of the rocker assembly.

[0006] According to one aspect of the disclosure, a vehicle rocker assembly includes one or more of a sill outer or sill inner to define an elongated hollow interior. The vehicle rocker assembly also includes a rocker insert disposed within the hollow interior. The rocker insert includes a first stiffening member having a top wall, a bottom wall, and a side wall. The rocker insert also includes a second stiffening member including a plurality of wall sections, each including an upper portion that engages the top wall and a lower portion that engages the bottom wall at a location spaced along the length of the rocker insert from the upper portion. The top and bottom walls of the first stiffening member are configured to be supported by the second stiffening member upon an inboard lateral impact force to enhance the lateral bending strength of the rocker insert.

[0007] According to another aspect of the disclosure, a rocker insert is provided that is configured to be disposed within an elongated hollow interior defined by one or more of an inboard wall portion of a sill inner and an outboard wall portion of a sill outer. The rocker insert includes a first stiffening member having a top wall, a bottom wall, and a side wall. The rocker insert also includes a second stiffening member including a plurality of wall sections, each including an upper portion that engages the top wall and a lower portion that engages the bottom wall at a location spaced along the length of the rocker insert from the upper portion. The top and bottom walls of the first stiffening member are configured to be supported by the second stiffening member upon an inboard lateral impact force to enhance the lateral bending strength of the rocker insert.

[0008] Implementations of the present disclosure may include one or more of the following optional features: In some examples, an upper portion of each of the plurality of wall sections engages at a first location along the length of the rocker insert and a lower portion engages at a second location along the length of the rocker insert, the distance between the first location and the second location being substantially the same for each of the plurality of wall sections along the rocker insert.

[0009] In some examples, the top wall includes a flange portion that extends diagonally from the remainder of the top wall.

[0010] In some examples, the bottom wall includes a flange portion that extends diagonally from the remainder of the bottom wall.

[0011] In some examples, the top wall includes a flange portion extending diagonally from a remainder of the top wall, and the bottom wall includes a flange portion extending diagonally from a remainder of the bottom wall.

[0012] In some instances, the flange portion of the top wall extends at an angle of approximately 80-100 degrees from the remainder of the top wall.

[0013] In some examples, the flange portion of the bottom wall extends at an angle of approximately 80-100 degrees from the remainder of the bottom wall.

[0014] In some examples, one or more of the top wall flange portion and the bottom wall flange portion are configured to be coupled to a sill outer instead of a conventional sill inner.

[0015] In some examples, one or more of the top wall flange portion and the bottom wall flange portion are configured to be coupled to a sill inner instead of a conventional sill outer.

[0016] In some examples, the sidewall includes a recess.

[0017] 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]

[0018] [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 a second stiffening member of the rocker insert shown in FIG. 4. [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 a second stiffening member 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 a second stiffening member of the rocker insert shown in FIG. 13. [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 an enlarged perspective view of a second stiffening member of the rocker insert shown in FIG. 16. [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 a second stiffening member 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 a second stiffening member of the rocker insert shown in FIG. 22. [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 a second stiffening member of the rocker insert shown in FIG. 25. [Figure 28] FIG. 13 is a perspective view of another example of a rocker insert. [Figure 29] FIG. 29 is an enlarged side view of the rocker insert shown in FIG. 28. [Diagram 30] FIG. 29 is a perspective view of a second stiffening member of the rocker insert shown in FIG. 28. [Diagram 31] FIG. 13 is a perspective view of another example of a rocker insert. [Diagram 32] FIG. 32 is an end view of the rocker insert shown in FIG. [Diagram 33] FIG. 32 is an exploded perspective view of the second stiffening member of the rocker insert shown in FIG. 31. [Diagram 34] FIG. 13 is a perspective view of another example of a rocker insert. [Diagram 35] FIG. 35 is an end view of the rocker insert shown in FIG. [Diagram 36] FIG. 35 is an exploded perspective view of the second stiffening member of the rocker insert shown in FIG. 34. [Figure 37] FIG. 13 is a perspective view of another example of a rocker insert. [Figure 38] FIG. 38 is an end view of the rocker insert shown in FIG. 37. [Figure 39] FIG. 38 is an exploded perspective view of the second stiffening member of the rocker insert shown in FIG. 37. [Diagram 40] FIG. 13 is a perspective view of another example of a rocker insert. [Diagram 41] FIG. 41 is an end view of the rocker insert shown in FIG. 40. [Diagram 42] FIG. 41 is an exploded perspective view of the second stiffening member of the rocker insert shown in FIG. 40. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] Like reference numbers refer to like parts throughout the drawings.

[0020] Referring now to the drawings and the illustrative embodiments depicted therein, beam components for a vehicle 100, such as for a body structure or frame 102 as shown in Figures 1 and 2, are provided. 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 Figures 1 and 2, the vehicle frame 102 has various structural components, including B-pillars, hinge pillars, floor cross members 106, 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 108 to distribute the battery weight and establish a low center of gravity for the vehicle.

[0021] The beam components disclosed herein may be rocker inserts, B-pillars, or battery tray side members, or other structural components that may benefit from the impact energy management properties provided and disclosed herein. The vehicle rocker components include one or more sill panels, such as sill inner panel 12 and sill outer panel 14, attached together about an interior area 16, where the terms "inner" and "outer" refer to the inward or inward facing directions 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 the outer section of a battery tray 104, where a floor cross member 106 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.

[0022] 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.

[0023] Additionally, the rocker inserts disclosed herein may be formed from one or more pieces of sheet material, such as by roll forming sheet metal, to provide a relatively high strength (against shear and axial loads) and low weight structure compared to typical rocker panels, thereby allowing, for example, the corresponding vehicle component sill panel (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 may include a variety of shapes and thicknesses for the desired application of the vehicle component. Additionally, some embodiments of the rocker insert may include aluminum extrusions combined with sheet metal material, such as that shown in FIG. 28.

[0024] 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.

[0025] 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 FIG. 3 extend continuously longitudinally along the edges of the rocker components, although it is contemplated that the flanges may be trimmed in selected areas to facilitate frame mounting or reduce weight.

[0026] 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.

[0027] The first sill panel 12, i.e., the inner panel of the vehicle rocker assembly 10, has an interior wall 26 or inboard wall portion that is substantially planar. The interior 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 interior wall 26 and the upper and lower walls 28, 30. The corner transitions are also defined by longitudinal bends in the plate material forming the first sill panel 12, such as metal plates (e.g., advanced high strength steel or aluminum plates). Similarly, the upper and lower walls 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 FIG. 3, the upper and lower flanges 18, 20 are substantially planar and oriented in parallel alignment with the planar extent of the interior 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 that are greater or less than those 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.

[0028] 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 exterior wall 32 or outboard wall portion 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 exterior wall 32 and the upper and lower walls 34, 36 are 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 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 plate 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 outer wall 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.

[0029] 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 slightly angled from being 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, 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 inner or outer walls that are not vertically oriented) for corresponding vehicle designs. It is also contemplated that in other examples, 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.

[0030] 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 first stiffening member 41 including a top wall 80, a bottom wall 82, and a first side wall 84. In the example shown in Figures 3 and 4, the first stiffening member includes a top wall 80, a bottom wall 82 disposed generally parallel to the top wall 80, and a first side wall 84 extending integrally between the top wall 80 and the bottom wall 82. As a result, the cross section of the first stiffening member includes a C-shape. The top wall 80, the bottom wall 82, and the side wall 84 define a channel along the length of the rocker insert. In one example, the top wall 80 and the bottom wall 82 have a width that spans at least 50% of the width between the outer sill 14 and the inner sill 12. In another example, the top wall 80 and the bottom wall 82 have a width that spans more than 50% of the width between the outer sill 14 and the inner sill 12.

[0031] 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 illustrated example, both the top wall 80 and the bottom wall 82 have flange portions 88 extending diagonally 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 in the range of 25-125 degrees, angles in the range of 35-115 degrees, angles in the range of 45-105 degrees, angles in the range of 60-100 degrees, angles in the range of 80-100 degrees, and angles in the range of 85-95 degrees.

[0032] 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 other vehicle component. In one example, one or more of the top wall flange portion and the bottom wall flange portion are coupled to the sill inner. For example, the rocker insert can replace a conventional sill outer such that a separate sill outer is not required. In another example, one or more of the top wall flange portion and the bottom wall flange portion are coupled to the sill outer. In this case, the rocker insert can replace a conventional sill inner such that a separate sill inner is not required. In one example, the coupling of the one or more flange portions to the sill inner or sill outer is a direct coupling, such as by welding. However, various other configurations are contemplated, including, but not limited to, an indirect coupling, such that another component is disposed between the flange portion and the sill inner or sill outer.

[0033] Further, in the illustrated example, the sidewalls 84 curve outward from both the top wall 80 and the bottom wall 82, then curve back inward into a channel to meet at the recess 90. In some examples, the recess 90 curves to have a generally U-shape that forms a stiffening channel along the sidewall 84. The depth and extent of the stiffening channel can vary based on the configuration desires, hardness, ductility, and thickness of the sheet material, among other considerations. In additional examples, additional stiffening channels can be formed in the sidewalls, or the stiffening channels can be omitted or shaped differently. In some examples, one or more of the top wall 80 or bottom wall 82 can include cutouts to accommodate other vehicle components without departing from the spirit of the present invention.

[0034] With further reference to the example shown in Figures 3 and 4, it is contemplated that one of the flange portions 88 of the side walls and / or 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.

[0035] 3 and 4, the rocker insert 40 also includes a second stiffening member 42. The second stiffening member 42 is at least partially disposed within a channel formed by the top wall 80, the bottom wall 82, and the side wall 84 of the first stiffening member 41. The stiffening member 42 includes at least one wall portion 46 that defines 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. 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. The second stiffening member 42 may be disposed along the entire length of the rocker insert 40, or in additional examples, may be disposed along a portion of the length of the rocker insert 40, such as more than 50% of the length of the rocker insert, or more than 80% of the length of the rocker insert. In addition, the second stiffening member 42 may be a single piece or may be segmented into multiple pieces that are mounted within a channel of the first stiffening member of the rocker insert, which may also be a single piece or multiple segmented pieces.

[0036] In one example, at least one wall portion 46 is formed from a flat sheet, typically coiled steel or aluminum, which is then cut and / or rolled or bent into the desired shape. It is also contemplated that at least one wall portion 46 may be constructed from another material having the desired strength requirements and / or from uncoiled steel or aluminum. It is also contemplated that at least one wall portion 46 may be formed by another method.

[0037] In some examples, the stiffening member 42 includes a plurality of wall portions 46 coupled to one another in the vehicle longitudinal direction, each wall portion 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. Furthermore, the leading edges 48 and the trailing edges 50 of each of the plurality of wall portions 46 are disposed at different positions along the length of the rocker insert 40. Furthermore, the second stiffening portion 42 includes a second wall portion 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 wall portion 46 such that the leading edge 48 and the trailing edge 50 of the second wall portion 46 are disposed at the same forward and rearward positions as the leading edge 48 and the trailing edge 50 of the second wall portion 46. In one example, the top wall portion 62 of the first wall portion 46 is coupled to the bottom wall portion 64 of the second wall portion 46, although various other configurations are contemplated. In one example, the first wall portion 46 and the second wall portion 46 are coupled by welding, although various other coupling methods are contemplated, including but not limited to the use of fasteners and / or adhesives. In one example, the top wall portion 62 of each of the plurality of wall sections engages at a first location along the length of the rocker insert, and the bottom wall portion 64 engages at a second location along the length of the rocker insert 40. In some examples, the distance between the first location and the second location is substantially the same for each of the plurality of wall sections along the rocker insert 40. In other examples, the distance between the first location and the second location is variable for each of the plurality of wall sections along the rocker insert 40.

[0038] 3 and 4, the cross-sectional shape of the second stiffening portion 42 includes a generally corrugated shape having a series of upper wall portions extending parallel to one another. The second stiffening portion 42 includes an upper wall portion 62 defined to include the highest point of the second stiffening portion 42 and a lower wall portion 64 defined as the lowest point of the second stiffening member 42. The wall sections of the second stiffening member 42 extend substantially perpendicular to the sidewall 86 of the first stiffening member 41 and are aligned or substantially aligned with an inboard lateral impact force on the vehicle. In other words, the wall sections extend generally perpendicularly from the sidewall 86 to the remainder of the channel along the width of the top wall 80 and bottom wall 82 of the first stiffening member 41.

[0039] In one example, the upper wall portion 62 of the second stiffening portion 42 extends between the first side edge 52 and the second side edge 54 and is configured to carry a load path laterally between the inboard and outboard side wall portions. In other words, the upper wall portion 62 of the second stiffening portion 42, if included, extends at least partially between the sill inner and sill outer. As shown in the example shown in Figures 3 and 4, the lower wall portion 64 of the second stiffening portion 42 also extends between the first side edge 52 and the second side edge 54 and is configured to carry a load path laterally between the outboard and outboard side wall portions.

[0040] The vehicle lateral direction generally extends across the width dimension of the vehicle. In contrast, the vehicle longitudinal direction generally extends along the length dimension of the vehicle. In some examples, the upper wall portion 62 may be disposed generally in a horizontal plane. The upper wall portion 62 of the second stiffening portion 42 is 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 of the rocker insert 40. Furthermore, the upper wall portion 62 of the second stiffening portion 42 extends at least partially between the sill wall portions of the sill inner 12 and the sill outer 14. In some examples, the second stiffening portion 42 may span the entire surface or may be disposed on only a portion of the surface. The upper wall portion 62 and the lower wall portion 64 may be of any shape and profile desired, including, but not limited to, the upper wall portion 62 being V-shaped or U-shaped and / or the lower wall portion 64 being V-shaped or U-shaped. It is also contemplated that the upper wall portion 62 and the lower wall portion 64 may be the same shape or may be different shapes from one another. It is further contemplated that the upper wall portion 62 and / or the lower wall portion 64 may be a single repeating shape, alternating shapes, or any pattern or other contemplated arrangement of wall shapes.

[0041] In some examples, the height of the upper wall portion 62 is the same as the depth of the lowest point on the lower wall portion 64. However, it is also contemplated that the height of the upper wall portion 62 and the depth of the lowest point on the lower wall portion 64 may differ from one another, such that the height of the upper wall portion 62 is greater than the depth of the lower wall portion 64, or vice versa. It is further contemplated that the height of the upper wall portion 62 may remain constant along the second stiffening member 42. However, it is also contemplated that the height of the upper wall portion 62 may be variable along the second stiffening member 42. Similarly, it is contemplated that the depth of the lower wall portion 64 may remain constant along the second stiffening member 42. However, it is also contemplated that the depth of the lower wall portion 64 may be variable along the second stiffening member 42.

[0042] In some examples, the width of the upper wall portion 62 is the same width as the lower wall portion 64. However, it is also contemplated that the width of the upper wall portion 62 measured from the center of one lower wall portion 64 to the center of an adjacent lower wall portion 64 and the width of the lower wall portion 64 measured from one upper wall portion 62 to another upper wall portion 62 may differ from one another such that the width of the upper wall portion 62 is greater than the width of the lower wall portion 64 or such that the width of the lower wall portion 64 is greater than the width of the upper wall portion 62. It is further contemplated that the width of the upper wall portion 62 may remain constant along the length of the second stiffening member 42. However, it is also contemplated that the width of the upper wall portion 62 may be variable along the second stiffening member 42. Similarly, it is contemplated that the width of the lower wall portion 64 remains constant along the length of the second stiffening member 42. However, it is also contemplated that the width of the lower wall portion 64 may be variable along the second stiffening member 42.

[0043] In some examples, the lower wall portion 64 has a width of approximately 0.5-1.5 mm. In other examples, the lower wall portion 64 has a width of approximately 0.8-1.3 mm. In yet other examples, the lower wall portion 64 has a width of approximately 0.9-1.1 mm. In one example, the lower wall portion 64 has a width of approximately 0.9 mm. In another example, the lower wall portion 64 has a width of approximately 1.1 mm. However, various other widths of the lower wall portion 64 are contemplated.

[0044] In some examples, the wall portions 46 are spaced apart by 100 mm or less. In other examples, the wall portions 46 are spaced apart by 75 mm or less. In other examples, the wall portions 46 are spaced apart by 50 mm or less.

[0045] In the example shown in Figures 3 and 4, the cross-sectional shape begins with a top wall portion 62, which is a generally flat surface. The second stiffening member 42 then changes to an angled portion 68 that extends diagonally downward before reaching a bottom wall portion 64, which is another generally flat surface. Another angled portion 68 extends upward from the flat surface of the bottom wall portion 64 toward the second top wall portion 62. In the example shown, the angled portion 68 extends at an angle of approximately 45 degrees, although other angles between 15 and 105 degrees are contemplated. The angled portion 68 provides a shape such that the distance between the first bottom wall portion 64 and the second bottom wall portion 64 is greater than the length of the top wall portion 62. Similarly, the distance between the first top wall portion 62 and the second top wall portion 62 is greater than the length of the bottom wall portion. 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 lower wall portion 64 and the upper wall portion 62 may include one or more reinforcing ribs 70 configured to provide additional strength to the second stiffening member 42. In the illustrated example, the transition between the angled portion 68 and the upper / lower wall portions 62, 64 and near the reinforcing ribs 70 is a curved angle, although various other configurations are contemplated, including sharper transitions.

[0046] It is also contemplated that the upper and lower wall portions 62, 64 of the second stiffening member 42 may be coupled to the top and bottom walls 80, 82, respectively, as described above. Typically, this coupling is achieved by welding, but other processes are contemplated, including but not limited to fasteners or adhesives. The top and bottom walls 80, 82 of the first stiffening member 41 are configured to be supported by the second stiffening member 42 when subjected to an inboard lateral impact force to increase the lateral bending strength of the rocker insert. In other words, the integration of the first stiffening member 41 and the second stiffening member 42 in the configuration as described provides a cooperative structural effect that increases the lateral bending strength of the rocker insert 40, leading to a lower risk of failure or buckling threshold of the rocker insert when subjected to a lateral impact force, which in turn may increase the battery package space, the resulting vehicle range, and the overall safety of the vehicle.

[0047] 10-12, rocker assembly 110 includes similar features as those discussed above with respect to rocker assembly 10 shown in FIGS. 1-9B, including, but not limited to, a sill outer, a sill inner, and a rocker insert 140 disposed within an elongated interior of the sill structure. Rocker insert 140 similarly includes a first stiffening member 141 that, in conjunction with rocker insert 140, defines a top wall 180, a bottom wall 182, and a sidewall 184 integrally connecting between the top wall and the bottom wall. Rocker insert 140 also similarly includes a second stiffening member 142 that includes a wall portion 146 having a leading edge 148 and a trailing edge 150 disposed at different positions along the length of rocker insert 140. However, as illustrated in the example shown in FIGS. 10-12, angled portion 168 of second stiffening member 142 extends at a smaller angle than the example shown in FIGS. 1-9B. More specifically, the angled portion 168 of the second stiffening member 142 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 upper wall portion 162 and the second upper wall portion 162 is just slightly greater than the width of the lower wall portion 164. Similarly, as shown in FIG. 11 , the distance between the first lower wall portion 164 and the second lower wall portion 164 is just slightly greater than the width of the upper wall portion 162.

[0048] 13-15, rocker assembly 210 includes similar features as discussed above with respect to rocker assembly 10 shown in FIGS. 1-9B, including, but not limited to, a sill outer, a sill inner, and a rocker insert 240 disposed within an elongated interior of the sill structure. Rocker insert 240 similarly includes a first stiffening member 241 that, in conjunction with rocker insert 240, defines a top wall 280, a bottom wall 282, and a side wall 284 integrally connecting between the top wall and the bottom wall. Rocker insert 240 also similarly includes a second stiffening member 242 that includes a wall portion 246 having a leading edge 248 and a trailing edge 250 disposed at different positions along the length of rocker insert 240. 10-12, the angled portion 268 of the second stiffening member 242 extends at approximately a 90 degree angle before reaching the reinforcing rib 270 and then continues to extend approximately perpendicular to the upper and lower wall portions 262, 264. As such, the distance between the first upper and second upper wall portions 262 is approximately equal to the width of the lower wall portion 264. Similarly, as shown in FIG. 11, the distance between the first lower wall portion 264 and the second lower wall portion 264 is approximately equal to the width of the upper wall portion 262.

[0049] 16-18, rocker assembly 310 includes similar features as discussed above with respect to rocker assembly 10 shown in FIGS. 1-9B, including, but not limited to, a sill outer, a sill inner, and a rocker insert 340 disposed within an elongated interior of the sill structure. Rocker insert 340 similarly includes a first stiffening member 341 that, in conjunction with rocker insert 340, defines a top wall 380, a bottom wall 382, ​​and a side wall 384 integrally connecting between the top wall and the bottom wall. Rocker insert 340 also similarly includes a second stiffening member 342 that includes a wall portion 346 having leading edges 348 and trailing edges 350 disposed at different positions along the length of rocker insert 340. However, as shown in the example illustrated in Figures 10-12, the angled portion 368 of the second stiffening member 342 extends at a generally 90 degree angle from the top wall portion 362 before reaching the reinforcing rib 370, and then continues inwardly from the reinforcing rib 370 and extends diagonally toward the top wall portion 362. Thus, the distance between the first top wall portion 362 and the second top wall portion 362 is less than the width of the bottom wall portion 364. Similarly, as shown in Figure 11, the distance between the first bottom wall portion 364 and the second bottom wall portion 364 is less than the width of the top wall portion 362.

[0050] 19-22, rocker assembly 410 includes similar features as described above with respect to rocker assembly 10 shown in FIGS. 1-9B, including, but not limited to, a sill outer, a sill inner, and a rocker insert 440 disposed within an elongated interior of the sill structure. Rocker insert 440 similarly includes a first stiffening member 441 that defines, in conjunction with rocker insert 440, a top wall 480, a bottom wall 482, and a side wall 484 integrally connecting between the top wall and the bottom wall. Rocker insert 440 also similarly includes a second stiffening member 424 that includes a wall portion 446 having a leading edge 448 and a trailing edge 450 disposed at different positions along the length of rocker insert 440. Additionally, second stiffening member 424 is similar in shape to the shapes described with respect to the examples shown in FIGS. 1-9B. However, second stiffening member 42 includes a second structure having an identical shape disposed therein. In this example, the upper wall portion 462 of the second stiffening member 424 is coupled to the top wall 80 of the first stiffening member 444. Additionally, the lower wall portion 464 of the second stiffening member 424 is coupled to the bottom wall 482 of the first stiffening member 441. As additionally shown in FIGS. 19-24, the reinforcing ribs 470 may have a more angular shape rather than the more curved shape shown in the example of FIGS. 1-9B. It is further contemplated that the reinforcing ribs 470 may be positioned at an angled portion closer to the upper wall portion 462 or closer to the lower wall portion 464, as desired.

[0051] 22-24, rocker assembly 510 includes similar features as those discussed above with respect to rocker assembly 10 shown in FIGS. 1-9B, including, but not limited to, a sill outer, a sill inner, and a rocker insert 540 disposed within an elongated interior of the sill structure. Rocker insert 540 similarly includes a first stiffening member 541 that, in conjunction with rocker insert 540, defines a top wall 580, a bottom wall 582, and a side wall 584 integrally connecting between the top wall and the bottom wall. Rocker insert 540 also similarly includes a second stiffening member 542 that includes a wall portion 546 having leading edges 548 and trailing edges 550 disposed at different positions along the length of rocker insert 540. However, as shown in the example shown in FIGS. 22-24, angled portion 568 of second stiffening member 542 extends at a greater angle than shown in FIGS. 1-9B. The angle of extension is greater than 90 degrees and may range from 95 to 130 degrees. Further, upon reaching the reinforcing rib 570, the angled portion 568 extends back at a similar angle toward the bottom wall portion 564. As such, the distance between the first top wall portion 562 and the second top wall portion 562 is approximately equal to the width of the bottom wall portion 564. Similarly, as shown in FIG. 23, the distance between the first bottom wall portion 564 and the second bottom wall portion 564 is approximately equal to the width of the top wall portion 562.

[0052] With reference to the example shown in Figures 25-27, rocker assembly 610 includes similar features as those discussed above with respect to rocker assembly 10 shown in Figures 1-9B, including, but not limited to, a sill outer, a sill inner, and a rocker insert 640 disposed within an elongated interior of the sill structure. Rocker insert 640 similarly includes a first stiffening member 641 having a top wall 680, a bottom wall 682, and a side wall 684 integrally connecting between the top wall and the bottom wall in conjunction with rocker insert 640. Rocker insert 640 also similarly includes a second stiffening member 642 having a wall portion 646 having leading edges 648 and trailing edges 650 disposed at different positions along the length of rocker insert 640. Additionally, the example shown in Figures 25-27 has similar angles of extension of the angled portions as the example shown in Figures 22-24. 25-27, however, the angled portion 668 of the second stiffening member 642 does not include reinforcing ribs, but instead has a smooth curve extending from the upper wall portion 662 to the lower wall portion 664. As such, the distance between the first upper wall portion 662 and the second upper wall portion 662 is approximately equal to the width of the lower wall portion 664. Similarly, as shown in FIG. 23, the distance between the first lower wall portion 664 and the second lower wall portion 664 is approximately equal to the width of the upper wall portion 662.

[0053] 28-30, a rocker insert 740 includes similar features as those discussed above with respect to the rocker assembly 10 and corresponding insert 40 shown in FIGS. 1-9B, including a first stiffening member 741 having a top wall 780, a bottom wall 782, and a side wall 784, and a second stiffening member 742 including a plurality of wall sections 768 each including an upper wall portion 762 engaged with the top wall 780 and a lower wall portion 764 engaged with the bottom wall 782 at a spaced apart location along the length of the rocker insert from the engagement of the upper wall portion. The plurality of wall sections 768 of the second stiffening member 742 extend perpendicular to the side wall 784 of the first stiffening member and are axially aligned with an inboard lateral impact force on the vehicle. In some examples, the second stiffening member 742 can be an aluminum extrusion, such as that shown in FIG. 28, which can provide additional shape from a shape formed from a sheet of metal. For example, as shown in FIG. 28, the extruded second stiffening member 742 includes an intermediate wall 792 that extends between the wall sections 768 that span between the top and bottom walls 780, 782 of the first stiffening member. In this manner, the intermediate wall 792 on the extruded second stiffening member 742 can function to further reinforce the top and bottom walls 780, 782 from one another. Furthermore, in additional examples, the second stiffening member when formed by extrusion can have a variety of alternative cross-sectional shapes and features, such as a honeycomb or lattice shape. Furthermore, the second stiffening member when formed by extrusion can be a piece that is segmented along its length, such as a piece formed by cutting an elongated extrusion (wherein the wall sections are continuous along the length of the extrusion) into pieces and orienting them in parallel along the channels of the first stiffening member. Thus, the second stiffening member 742 may include an extrusion having a plurality of wall sections 768 arranged in the extrusion direction, as shown in FIG.

[0054] 31-33, rocker assembly 810 includes similar features as described above with respect to rocker assembly 10 shown in FIGS. 1-9B, including, but not limited to, a sill outer, a sill inner, and a rocker insert 840 disposed within the elongated interior of the sill structure. Rocker insert 840 similarly includes a first stiffening member 841 that defines, in conjunction with rocker insert 840, a top wall 880, a bottom wall 882, and a side wall 884 integrally connecting between the top wall and the bottom wall. However, compared to first stiffening member 41 of FIG. 3, recess 890 in side wall 884 protrudes a greater distance or proportion toward flange 888 that connects to the inboard side wall portion of the sill structure. By doing so, the interior space within the channel defined by first stiffening member 841 is reduced to provide a shorter minimum distance for second stiffening member 842 to extend between recess 890 and the inboard side wall portion of the sill structure.

[0055] The rocker insert 840 shown in Figures 31-33 similarly includes a second stiffening member 842 including wall sections 846 each including an upper wall portion 862 engaged with a top wall 880 and a lower wall portion 864 engaged with a bottom wall 882 at a location spaced apart along the length of the rocker insert from the upper wall portion 862. The wall section 846 of the second stiffening member 842 extends perpendicular to the side wall 884 of the first stiffening member and is axially aligned with an inboard lateral impact force on the vehicle. The wall section 846 includes angled portions extending between the upper wall portion 862 and the lower wall portion 864 to define an undulating structure having peaks at the upper wall portion 862 and valleys at the lower wall portion 864 alternating at spaced apart locations in a repeating manner along the length of the rocker insert 840. 1-9B, however, the second stiffening member 842 is segmented along its length such that it is formed from a plurality of separate repeating sections along the length of the second stiffening member, which are formed of the same shape such that the sections can be formed into a single beam in a direction aligned with the wall direction and potential inboard lateral impact direction and then cut along the length of the beam to form the individual sections or segments.

[0056] With reference to the example shown in FIGS. 34-36, rocker assembly 910 includes similar features as those discussed above with respect to rocker assembly 810 shown in FIGS. 31-33, including, but not limited to, a sill outer, a sill inner, and a rocker insert 940 configured to be disposed within an elongated interior of the sill structure. Rocker insert 940 similarly includes a first stiffening member 941 that, in conjunction with rocker insert 840, defines a top wall 980, a bottom wall 982, and a side wall 984 integrally connecting between the top and bottom walls. Rocker insert 940 also similarly includes a second stiffening member 942 that includes an upper wall portion 962, a lower wall portion 964, and a wall section 946 that includes an angled portion that extends between the upper and lower wall portions 962, 964 to define a wave-shaped structure. Additionally, second stiffening member 942 is also segmented along its length such that it is formed from a plurality of separate repeating sections. 35 , the recess 990 in the sidewall 984 protrudes a shorter distance toward the flange 988 and has a shorter height above the sidewall 984. The recess 990 forms a non-planar component along the length of the rocker insert 940, and the outboard edge of the second stiffening member 942 is shaped to fit within the non-planar component. More specifically, the shape of the outboard edge of the second stiffening member generally fits and mates with the shape provided by the sidewall 984.

[0057] With reference to the example shown in FIGS. 37-39, rocker assembly 1010 includes similar features as those discussed above with respect to rocker assembly 810 shown in FIGS. 31-33, including, but not limited to, a sill outer, a sill inner, and a rocker insert 1040 configured to be disposed within an elongated interior of the sill structure. Rocker insert 1040 similarly includes a first stiffening member 1041 that, in conjunction with rocker insert 1040, defines a top wall 1080, a bottom wall 1082, and a side wall 1084 integrally connecting between the top wall and the bottom wall. Rocker insert 1040 also similarly includes a second stiffening member 1042 that includes a wall section 1046 that defines a wave-like structure. Additionally, second stiffening member 1042 is also segmented along its length such that it is formed from a plurality of separate repeating sections. However, side wall 1084 is devoid of any recesses or concave components, such as to have a substantially planar shape, as shown in FIG. 38. The outboard edge of the second stiffening member 1042 is shaped to fit the planar components, but the upper and lower outboard corners of the second stiffening member 1042 have chamfer angles to avoid interaction with the curved upper and lower corners on the first stiffening member that separate the side wall 1084 from the top wall 1080 and bottom wall 1082.

[0058] With reference to the example shown in FIGS. 40-42, the rocker assembly 1110 includes similar features as those discussed above with respect to the rocker assembly 1010 shown in FIGS. 37-39, including, but not limited to, a sill outer, a sill inner, and a rocker insert 1140 configured to be disposed within an elongated interior of the sill structure. The rocker insert 1140 similarly includes a first stiffening member 1141 that, in conjunction with the rocker insert 1140, defines a top wall 1180, a bottom wall 1182, and a side wall 1184 integrally connecting between the top wall and the bottom wall. The rocker insert 1140 also similarly includes a second stiffening member 1142 that includes wall sections 1146 that define a wave-shaped structure. Additionally, the second stiffening member 1142 is also segmented along its length such that it is formed from a plurality of separate repeating sections. Additionally, the side wall 1184 is devoid of any recesses or concave features as well, and the outboard edge of the second stiffener member 1142 is shaped to fit a planar feature. However, the upper and lower corners on the first stiffener member 1142 that separate the side wall 1184 from the top wall 1180 and bottom wall 1182 have a chamfer shape that corresponds to the chamfer angles at the upper and lower outboard corners of the second stiffener member 1142.

[0059] 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.

[0060] For purposes of this disclosure, the term "coupled" (in all its forms, coupled, connecting, connected, etc.) generally means that two components are joined directly or indirectly to one another. Such joining may be stationary in nature or movable in nature, may be achieved by the two components and any additional intermediate members being integrally formed with one another as a single unit, or by the two components, and may be permanent in nature or removable or releasable in nature, unless otherwise specified.

[0061] 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.

[0062] 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.

[0063] 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.

[0064] 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. 1. A rocker assembly for a vehicle, comprising: a sill structure having an inboard wall portion and an outboard wall portion defining an elongated interior therebetween; a rocker insert disposed within the elongated interior of the sill structure, a first stiffening member having a top wall, a bottom wall, and a side wall extending between the top wall and the bottom wall, the top wall, the bottom wall, and the side wall defining a channel; a second stiffening member at least partially disposed within the channel, the second stiffening member including a plurality of wall sections, each of the wall sections including an upper wall portion that engages the top wall and a lower wall portion that engages the bottom wall at a location spaced along a length of the rocker insert from the upper wall portion, the plurality of wall sections of the second stiffening member extending perpendicular to the sidewall of the first stiffening member and axially aligned with an inboard lateral impact force for the vehicle; Rocker inserts including A rocker assembly for a vehicle.

2. The rocker assembly of claim 1 , wherein said top wall includes a flange portion extending diagonally from a remainder of said top wall.

3. The rocker assembly of claim 1 , wherein said bottom wall includes a flange portion extending diagonally from a remainder of said bottom wall disposed parallel to said top wall.

4. the top wall includes a flange portion extending at a first angle from a remainder of the top wall; The rocker assembly of claim 1 , wherein the bottom wall includes a flange portion extending at a second angle from a remainder of the bottom wall.

5. The rocker assembly of claim 4 , wherein one or both of the flange portion of the top wall and the flange portion of the bottom wall are coupled to the interior sidewall portion of the sill structure.

6. The rocker assembly of claim 1 , wherein the top and bottom walls of the first stiffening member are configured to support the second stiffening member upon receipt of the inboard lateral impact force.

7. the top wall portions of each of the plurality of wall sections engage at a first location along a length of the rocker insert; the lower wall portion engages at a second location along the length of the rocker insert; The rocker assembly of claim 1 , wherein the distance between the first location and the second location is substantially the same for each of the plurality of wall sections along the rocker insert.

8. The rocker assembly of claim 1 , wherein the second stiffening member comprises a length that extends more than 50% of a length of the first stiffening member.

9. the second stiffening member includes a metal plate having a length extending along a longitudinal extent of the hollow interior; The locker assembly of claim 1 , wherein the plurality of wall sections define a corrugated configuration having alternating peaks and valleys spaced apart along the length of the metal plate.

10. The rocker assembly of claim 1 , wherein the side wall includes a recess that projects inwardly toward the interior sidewall portion of the sill structure.

11. 1. A rocker insert configured to be disposed along an elongated hollow interior of a vehicle sill structure, comprising: a first stiffening member having a top wall, a bottom wall, and a side wall extending integrally between said top wall, said bottom wall, and said side wall together defining a channel; a second stiffening member disposed at least partially within the channel, the second stiffening member including a plurality of wall sections, each wall section including an upper wall portion that engages the top wall and a lower wall portion that engages the bottom wall at a location spaced along a length of the rocker insert from the upper wall portion; the plurality of wall sections of the second stiffening member extend perpendicular to the sidewall of the first stiffening member and are axially aligned with an inboard lateral impact force against the vehicle sill structure; the plurality of wall sections include an angled portion extending between the upper wall portion and the lower wall portion and configured to support the top and bottom walls of the first stiffening member upon receipt of the inboard lateral impact force. Rocker insert.

12. the top wall includes a flange portion extending obliquely from a remainder of the top wall; The rocker insert of claim 11 , wherein the flange portion is configured to mate with an inboard wall of the vehicle sill structure.

13. The rocker insert of claim 11 , wherein the bottom wall includes a flange portion extending diagonally from a remainder of the bottom wall that is disposed parallel to the top wall.

14. the top wall includes an upper flange portion extending at a first angle from a remainder of the top wall; The rocker insert of claim 11 , wherein the bottom wall includes a lower flange portion extending at a second angle from a remainder of the bottom wall.

15. the top wall portions of each of the plurality of wall sections engage at a first location along a length of the rocker insert; the lower wall portion engages at a second location along the length of the rocker insert; The rocker insert of claim 11 , wherein the distance between the first location and the second location is substantially the same for each of the plurality of wall sections along the rocker insert.

16. The rocker insert of claim 11 , wherein the second stiffening member includes a plurality of separate repeating sections along a length of the second stiffening member.

17. the second stiffening member includes a metal plate having a length extending along a longitudinal extent of the hollow interior; The rocker insert of claim 11 , wherein the plurality of wall sections define a corrugated configuration having alternating peaks and valleys spaced apart along the length of the metal plate.

18. the sidewall of the first stiffening member includes a non-planar component along a length of the rocker insert; The rocker insert of claim 11 , wherein an outboard edge of the second stiffening member is shaped to match the non-planar component.

19. 1. A vehicle beam component comprising: a first stiffening member having a first wall, a second wall disposed parallel to the first wall, and a third wall extending between the first wall and the second wall, the first wall, the second wall, and the third wall defining a channel; a second stiffening member disposed at least partially within the channel, the second stiffening member including a plurality of wall sections each including a first end portion that engages the first wall and a second end portion that engages the second wall at a spaced location along a length of the vehicle beam component from engagement with the first wall portion; the plurality of wall sections include an angled portion extending between the upper wall portion and the lower wall portion and configured to support the top wall and the bottom wall of the first stiffening member upon an inboard lateral impact force; the first wall and the second wall of the first stiffening member are configured to be supported by the second stiffening member when subjected to an inboard lateral impact force. Vehicle beam components.

20. the plurality of wall sections of the second stiffening member extend perpendicular to the third wall of the first stiffening member so as to be substantially aligned with the inboard lateral impact force; The vehicle beam component of claim 19 , wherein the second stiffening member includes a plurality of separate repeating sections along a length of the vehicle beam component.

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