Rocker assembly insert with opposed collapse channels - Patents.com

Abstract

The vehicle rocker assembly includes an outer sill member and an inner sill member longitudinally attached along the outer sill member to define a hollow space along and between the inner and outer sill members. A tubular insert is disposed within the hollow space so as to extend longitudinally along the hollow space. The tubular insert has collapse control features extending longitudinally along walls of the tubular insert, such as upper and lower walls on opposite sides of the interior volume. The tubular insert is configured to absorb a side impact force at the outer sill member by laterally deforming the tubular insert at the collapse control features to provide accordion-style lateral collapse.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application No. 63 / 073,120, filed September 1, 2020, the disclosure of which is considered a part of this application and is incorporated by reference in its entirety herein.

[0002] The present disclosure relates to rocker and sill assemblies for vehicles, such as rocker structures having reinforcing inserts. [Background technology]

[0003] Vehicles typically have a rigid frame and body structure commonly referred to as a unibody frame. The vehicle frame and body structure is designed to support the vehicle during operation and to receive and absorb a certain level of impact forces, such as to prevent intrusion into the passenger compartment, trunk, engine compartment, etc., in accordance with insurance requirements and other regulatory and legal requirements. With respect to the impact resistant reinforcements and structural beams used in the body or frame of a vehicle, it is generally known that these beams may be reinforced with internal inserts to increase stiffness. Rocker assemblies extend longitudinally along the bottom of the unibody vehicle frame and are known to have inserts to increase stiffness, such as to reduce intrusion in side impacts. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Korean Utility Model Registration No. 20-0182555 Summary of the Invention [Means for solving the problem]

[0005] The present disclosure provides a rocker assembly for a vehicle body frame including a hollow exterior structure formed with attached inner and outer sill members. A reinforcing insert is disposed within and extends longitudinally along an interior space of the hollow exterior structure. The reinforcing insert has a cross-sectional profile that is generally consistent along the length of the rocker assembly, such as to provide a tubular shape with one or more enclosed tubular sections. The reinforcing insert may be roll formed, stamped or extruded to have a consistent cross-sectional profile, such as a closed or other tubular cross-sectional shape. To enhance impact energy absorption from a side impact force applied to the outer sill member, such as a side pillar impact body, the reinforcing insert includes one or more lateral crush control features. The crush control features help control lateral compression and deformation of the rocker assembly during impact forces, such as by causing the side impact force to laterally deform the tubular insert in an accordion-style lateral collapse. The crush control features may be provided as crush channels formed along the reinforcing insert, such as to protrude into the interior volume of the tubular shape. The crush channels may be located on opposite sides of the reinforcing insert, such as upper and lower walls of an enclosed tubular section of the reinforcing insert, so that a side impact force causes the tubular insert to deform laterally at the crush channels, providing an inward or outward folding deformation, such as an accordion-style lateral collapse. According to one aspect of the disclosure, a vehicle rocker assembly includes an outer sill member and an inner sill member longitudinally attached along the outer sill member to define a hollow space along and between the inner and outer sill members. A tubular insert is disposed within the hollow space to extend longitudinally along the hollow space. The tubular insert has upper and lower walls that bound opposing sides of an interior volume of the tubular insert. The upper and / or lower walls of the tubular insert have a collapse channel extending longitudinally along the tubular insert. The one or more collapse channels are configured to laterally deform the tubular insert to provide an accordion-style lateral collapse in response to a side impact force at the outer sill member to at least partially absorb the side impact force.

[0006] Implementations of the present disclosure may include one or more of the following optional features: In some implementations, the tubular insert includes an outer tubular section and an inner tubular section integrally formed together and disposed laterally adjacent to one another. The outer tubular section and the inner tubular section may share a common central wall that extends vertically between the upper and lower walls of the tubular insert. In some examples, the outer tubular section has an outer wall that faces the outer sill member and is integrally interconnected between the upper and lower walls of the tubular insert.

[0007] In some implementations, one or more collapse channels project into the interior volume of the tubular insert, and may be disposed in the upper and lower walls on opposite sides of the interior volume, with two or more channels. In some examples, the collapse channels may be mirrored across the interior volume of the tubular insert, such as in the outer tubular section or the inner tubular section. In other examples, the collapse channels are staggered vertically across one another. Additionally, the upper and lower walls of the tubular insert may be disposed in planar alignment with one another or may have a tapered shape. The collapse channels in some examples are aligned vertically across the interior volume of the outer tubular section, such as perpendicular to the upper and lower walls. The collapse channels of the tubular insert may be configured to deform simultaneously under side impact forces at the outer sill member.

[0008] With regard to securing the tubular insert, a bracket may be attached between the upper flanges of the outer and inner sill members. The bracket is attached to and supports the tubular insert within the hollow space. In some implementations, the tubular insert also includes a flange attached between the upper flanges of the outer and inner sill members. The flange supports the tubular insert within the hollow space. Additionally, the tubular insert may be secured at an inner surface of the outer or inner sill members, such as via at least one of a weld, fasteners, or adhesive.

[0009] In some examples, the tubular insert comprises a metal sheet formed to have outer and inner tubular sections sharing a common central wall, the outer and inner tubular sections being disposed laterally adjacent to one another, Alternatively, the tubular insert may be longitudinally extruded to have the outer and inner tubular sections sharing a common wall that integrally interconnects the upper and lower walls of the tubular insert.

[0010] The details of one or more implementations of the disclosure are set forth in the accompanying drawings and the description below. Other aspects, features, and advantages will become apparent from the description and drawings, and from the claims. [Brief description of the drawings]

[0011] [Figure 1] FIG. 2 is a side view of a vehicle profile, showing the location of the rocker assemblies in schematic form. [Diagram 2] FIG. 2 is a top perspective view of the vehicle of FIG. 1 showing the rocker assembly and various other structural beams. [Diagram 3] FIG. 2 is a top view of the rocker assembly. [Figure 4] FIG. 4 is a side view of the rocker assembly shown in FIG. [Figure 4A] FIG. 5 is a cross-sectional view of the rocker assembly taken along line AA in FIG. [Figure 4B] FIG. 5 is a cross-sectional view of the rocker assembly taken at line BB in FIG. [Diagram 5] FIG. 13 is a top view of another example of a rocker assembly. [Figure 6] FIG. 6 is a side view of the rocker assembly shown in FIG. [Figure 6A] FIG. 7 is a cross-sectional view of the rocker assembly taken along line AA in FIG. [Figure 6B] FIG. 7 is a cross-sectional view of the rocker assembly taken at line BB in FIG. [Figure 7] FIG. 13 is a top view of a further example of a rocker assembly. [Figure 8] FIG. 8 is a side view of the rocker assembly shown in FIG. [Figure 8A] FIG. 9 is a cross-sectional view of the rocker assembly taken along line AA in FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] Like reference numbers in the various drawings indicate like elements.

[0013] Referring now to the drawings and the exemplary embodiments depicted therein, a reinforced rocker assembly 10 is provided for a body structure or frame 102 of a vehicle 100, such as that shown in Figures 1 and 2. The vehicle frame and associated rocker assembly may have a variety of designs and configurations, such as for different makes and types of vehicles. For example, as shown in Figure 1, the vehicle 100 may operate its propulsion system at least in part with a battery, such as a traction battery or battery module. The battery may be supported on a battery tray 104, typically located between the axles and near the floor of the vehicle 100, to distribute the battery weight and establish a low center of gravity for the vehicle.

[0014] For example, as shown in Figures 3-4B, a vehicle rocker assembly 10 includes a hollow exterior structure 12 formed of an inner sill member 14 and an outer sill member 16, which may also be referred to as rocker panels or sections. The inner sill member 14 is attached longitudinally along the outer sill member 16 and defines an elongated hollow space 18 between the inner and outer sill members 14, 16. The inner and outer sill members 14, 16, which form the exterior structure 12, surround the elongated hollow space 18 between the inner and outer sill members 14, 16. A reinforcing insert 20 is disposed within the hollow space 18 of the exterior rocker structure 12 and extends longitudinally along at least a portion or longitudinal section of the hollow space 18. The reinforcing insert 20 has a cross-sectional profile that is generally consistent along its length, such as a tubular shape having one or more enclosed tubular portions. Thus, the reinforcing insert 20 may be referred to as a tubular insert.

[0015] The reinforcing insert 20 includes one or more lateral collapse control features for increasing impact energy absorption by controlling the lateral compression and deformation of the rocker assembly 10 subjected to side impact forces applied to the outer sill member, such as those applied by a side column impactor. For example, as shown in FIGS. 3-4A, the collapse channels 22 are positioned along opposing upper and lower sides of the reinforcing insert 20. The collapse channels 22 are positioned to allow the reinforcing insert 20 to collapse laterally like an accordion. Such an accordion-style collapse can limit cracking and material failure by controlling how the sections collapse. The controlled collapse provided by the collapse channels 22 also adds material stacking later in the event, leading to more energy absorption overall.

[0016] It is contemplated that the reinforcing inserts of the disclosed rocker assemblies may be incorporated into other types of structural beams, such as the frames and structures of automobiles and other vehicles. The reinforcing inserts may also be used within other structural frame components and impact energy management beams configured to receive impact loads at various sections of the beam and absorb such impact loads in a desired manner. For example, as shown in FIG. 2, the frame 102 of a vehicle 100 has multiple structural beams, one or all of which may include internal reinforcements as described herein.

[0017] To form the exterior structure 12, the inner sill member 14 has an upper flange 14a attached along with an upper flange 16a of the outer sill member 16. The inner sill member 14 also has a lower flange 14b of the inner sill member 14 attached along with a lower flange 16b of the outer sill member 16. Such attachment of the inner and outer sill members 14, 16 may be a direct contact engagement or may be indirectly attached using an intermediary such as a flange, plate, bracket, etc. sandwiched between the upper and lower flanges 14a, 14b, 16a, 16b. As shown in Figures 3-4B, the upper and lower flanges 14a, 14b, 16a, 16b are provided along the upper and lower edges of the respective inner and outer sill members 14, 16. The upper and lower flanges 14a, 14b, 16a, 16b are also substantially flat and oriented in a generally vertical configuration, such as for direct contact and attachment along several sections of the length of the rocker assembly 10 (FIG. 4A) and for indirect attachment at several discrete sections where the support bracket 62 is disposed between the flanges (FIG. 4B). The upper and lower flanges 14a, 14b, 16a, 16b are attached together via welding, although other examples of rocker assemblies may use adhesives and / or mechanical fasteners in addition to or instead of welding. The inner and outer sill members 14, 16 shown in FIG. 3 are steel. However, it is contemplated that other examples may include alternative or multiple materials, such as steel, aluminum, and / or composite materials.

[0018] The intermediate portions of the inner and outer sill members 14, 16 are generally shaped to have a generally concave cross-sectional shape, such as the exemplary C-shaped cross-section of the inner and outer sill members 14, 16 shown in Figures 4A and 4B. The intermediate portion of the inner sill member 14 has an upper wall section 24, an innermost wall section 26, and a lower wall section 28, each of which is generally planar in shape. Similarly, the intermediate portion of the outer sill member 16 has an upper wall section 30, an outermost wall section 32, and a lower wall section 34, each of which is generally planar in shape. As shown in Figures 4A and 4B, the upper wall sections 24, 30 have substantially equal lengths relative to the corresponding lower wall sections 26, 34. Additionally, the upper and lower wall sections 24, 26, 30, 34 are angled from the horizontal, and each pair of upper and lower wall sections is similarly angled. As a result of the substantially equal lengths and angles, the upper and lower flanges 14a, 14b, 16a, 16b shown in Figures 4A and 4B are vertically aligned with one another. In other examples, such as the example shown in Figure 8A, the upper and lower flanges of the exterior structure may be offset from one another. The cross-sectional profile of the inner and outer panels 14, 16 may be generally consistent along the length of the rocker assembly, such as that shown in the example shown in Figures 3-6, or may have some inconsistent features along the length to accommodate door pillar engagement, as shown in the example of Figures 7 and 8.

[0019] As shown in FIGS. 3-4B, the reinforcing insert 20 is disposed within the elongated hollow space 18 and extends longitudinally along the entire length of the inner sill member 14 and along a portion of the length of the outer sill member 16. In other examples, the reinforcing insert may extend along different longitudinal extents of the hollow exterior structure, such as within or beyond the length of the outer and inner sill members. The collapse control features of the reinforcing insert 20 may be integrally formed therein, such as a collapse channel 22 that extends consistently along the length of the reinforcing insert 20. As shown in FIGS. 4A and 4B, the collapse channel 22 projects into the interior volume 36 of both tubular shapes of the reinforcing insert 20. However, it is also contemplated that one or more collapse channels may project outwardly away from the interior volume along the top or bottom wall of the reinforcing insert. As shown in Figures 4A and 4B, the crush channels 22 are also disposed on opposite sides of the interior volume 36 so that side impact forces laterally deform the reinforcing insert 20 inwardly at the crush channels 22, such as to provide an accordion-style lateral crush pattern. In other examples, a single crush channel may be provided or additional crush channels may be utilized. The crush channels may be disposed in the upper and lower walls of the outer tubular section without a crush channel in the other tubular section or sections, or alternatively, the crush channels may be disposed in the upper and lower walls of the inner tubular section without a crush channel in the outer tubular section or sections, such as shown in Figure 8A.

[0020] The crush channels in some examples are configured to deform simultaneously under side impact forces at the outer sill member. For example, as shown in Figures 4A and 4B, the crush channels 22 are disposed on opposite sides of the reinforcing insert in an alignment that is generally perpendicular to the orientation of a horizontal side impact force. In this manner, the crush channels 22 may be mirror-spaced across the interior volumes of the outer and inner tubular sections such that they are vertically aligned with one another for optimized collapse as a result of a horizontal side impact force. In other examples, the crush channels may be laterally staggered across one another, such as laterally staggered across the enclosed interior volume, or staggered with the crush channels disposed on separate tubular sections of the reinforcing insert.

[0021] The reinforcing insert 20 has an upper wall 38 and a lower wall 40 that bound opposing sides of an interior volume 36 of the reinforcing insert 20. As shown in Figures 4A and 4B, the upper and lower walls 38, 40 of the reinforcing insert 20 are disposed in planar alignment with one another. In other examples, the upper and lower walls may be tapered or angled toward or away from one another, or may have a non-planar shape, such as a curved or rounded transition along the width of the respective walls. The upper and lower walls 38, 40 of the reinforcing insert 20 each have a collapse channel 22 that projects into the interior volume 36 and extends longitudinally along the respective upper and lower walls on opposing sides of the interior volume 36. Again, in other examples, one or more collapse channels may project outwardly from the interior volume. As also shown in Figures 4A and 4B, the reinforcing insert 20 includes an outer tubular section 42 and an inner tubular section 44 that are integrally formed together and disposed laterally adjacent to one another. The outer tubular section 42 and the inner tubular section 44 share a common central wall 46 which extends vertically between the upper and lower walls 38,40 of the reinforcing insert 20 and divides the interior volumes of the respective outer and inner tubular sections 42,44.

[0022] As further shown in Figures 4A and 4B, the outer tubular section 42 of the reinforcing insert 20 has an outer wall 48 integrally interconnected between the upper and lower walls 38, 40 of the reinforcing insert 20. The outer wall 48 faces and contacts the outermost wall section 32 of the outer sill member 16. Similarly, the inner tubular section 44 has an inner wall 50 integrally interconnected between the upper and lower walls 38, 40 of the reinforcing insert 20. The inner wall 50 faces and contacts the innermost wall section 26 of the inner sill member 14. Thus, the reinforcing insert may have a lateral width between the inner and outer walls sized to closely fit or occupy the distance between the inner and outer sills as shown in Figures 4A and 4B. However, in other examples, the reinforcing insert may be designed to closely fit only one of the inner and outer sill members and have a gap in the other, or alternatively have a gap on both sides to float in the space between the inner and outer sill members. 4A and 4B are spaced apart from the top wall sections 24, 30 and the bottom wall sections 28, 34. However, it is contemplated that the spacing may be reduced or substantially eliminated due to the ability of the collapse control features to cause inward deformation upon lateral impact forces outside of the rocker assembly, such as to deform into an accordion shape within the exterior structure of the rocker assembly.

[0023] To form the tubular insert 20 shown in Figures 3-4B, the metal sheet is roll-formed to have an outer tubular section 42 and an inner tubular section 44 laterally adjacent to one another, sharing a common central wall 46. The outer sections of the metal sheet forming the two adjacent tubular sections extend from opposite sides of the central section of the metal sheet forming the common central wall 46. As oriented in Figures 3-4B, the two adjacent tubular sections 14, 16 are defined on opposite sides of the common central wall 46 by upper walls 52, 54, lower walls 56, 58, outer wall 48 and inner wall 50. The crush channel 22 is roll-formed into the metal sheet at the upper walls 52, 54 and lower walls 56, 58. The crush channel 22 has a width of about 10%-40% of the width of the corresponding wall section (more preferably about 20%-30% of the wall width) and a depth approximately equal to the width dimension. As shown in Figures 4A and 4B, the crush channel 20 shown is semicircular in shape. It is also contemplated that the depth and size of the crush channels may be shallower, deeper, wider, narrower, or otherwise modified for desired lateral crush features.

[0024] The metal sheet used to form the reinforcing insert of Figures 4A and 4B is a steel material, such as advanced high strength steel (AHHS), having a thickness of 0.8 mm to 1.4 mm or about 1 mm to 1.5 mm. The sheet 12 may also have a tensile strength of about 800 to 2000 MPa (i.e., about 120 to 290 ksi). It is also contemplated that the reinforcing insert may be made of sheets having different thicknesses and may be made of one or a combination of different materials, such as steel, aluminum, and / or composites.

[0025] To hold the roll-formed sheet in the tubular shape of the reinforcing insert 20, one edge 60a of the sheet is attached via a weld to the lower end of the central wall 46, and the other edge 60b is attached via a weld to the top wall 52 near the upper end of the central wall 46. The top walls 52, 54 and bottom walls 56, 58 of adjacent tubular sections 42, 44 are substantially aligned with one another to form the respective top and bottom walls 38, 40 of the reinforcing insert. Additionally, the outer and inner walls 28, 30 are substantially parallel to one another and to the common central wall 18, and generally perpendicular to the top and bottom walls 20, 22, 24, 26. Additional examples of reinforcing inserts can take on various shapes and orientations from those shown in Figures 4A and 4B and can include alternative dimensional proportions, such as for different applications of the insert.

[0026] The reinforcing insert can be supported and / or attached within the external structure in a variety of ways. For example, a series of brackets 62 (FIG. 4B) are attached between the upper and lower flanges 14a, 14b, 16a, 16b of the outer and inner sill members 14, 16 spaced apart along the length of the reinforcing insert. As shown in FIG. 4B, the brackets 62 have an L-shape with an inner portion 64 attached to the upper and lower walls 38, 40 and an outer portion 66 attached by welding between the upper and lower flanges 14a, 14b, 16a, 16b to support the reinforcing insert 20 in the hollow space 18. In other examples, the reinforcing insert can also or alternatively be attached to the inner surface of the outer or inner sill members, such as via welding, fasteners and / or adhesives.

[0027] 5-6B, the reinforcing insert 120 is disposed within the hollow space 118 and extends longitudinally along the entire inner sill member 114 and along a portion of the outer sill member 116. The crush channel 122 of the reinforcing insert 120 is integrally formed therein and extends consistently along the length of the reinforcing insert 120. As shown in FIGS. 6A and 6B, the reinforcing insert 120 has an outer tubular section 142 and an inner tubular section 144 that are longitudinally extruded from an aluminum alloy or the like and share a common wall 146 that integrally interconnects the upper and lower walls 138, 140 of the reinforcing insert 120. The upper and lower walls 138, 140 that bound opposing sides of the interior volume 136 of the reinforcing insert 120 are disposed in planar, parallel alignment with one another. The crush channel 122 is extruded into the upper and lower walls 138, 140 to extend into the respective tubular shaped interior volumes 136 of the reinforcing insert 120. 6A and 6B have a V-shape to help initiate lateral collapse of the reinforcing insert at the crush channel. The crush channels 122 are disposed on opposite sides of the interior volume 136 to allow side impact forces to laterally deform the reinforcing insert 120 inward at the crush channel 122, such as to provide an accordion-style lateral collapse pattern.

[0028] As shown in Figures 6A and 6B, the reinforcing insert 120 includes an outer tubular section 142 and an inner tubular section 144 integrally formed together and disposed laterally adjacent to one another. The crush channels 122 are mirror-disposed throughout the interior volume 136 of the outer and inner tubular sections 142, 144 so as to be vertically aligned with one another. As also shown in Figures 6A and 6B, the outer tubular section 142 of the reinforcing insert 120 has an outer wall 148 integrally interconnected between the upper and lower walls 138, 140 of the reinforcing insert 120. The outer wall 148 faces and contacts the outermost wall section 132 of the outer sill member 116. Similarly, the inner tubular section 144 has an inner wall 150 integrally interconnected between the upper and lower walls 138, 140 of the reinforcing insert 120. The inner wall 150 faces and contacts the innermost wall section 126 of the inner sill member 114 .

[0029] To support the reinforcing insert 120 within the external structure 112, a series of brackets 162 are attached between the upper and lower flanges 114a, 114b, 116a, 116b of the outer and inner sill members 114, 116. As shown in FIG. 6B, the brackets 162 have an L-shape with an inner portion 164 attached to the upper and lower walls 138, 140 and an outer portion 166 attached between the upper and lower flanges 114a, 114b, 116a, 116b to support the reinforcing insert 120 in the hollow space 118. Attachment of the brackets to the reinforcing insert and external structure may be accomplished using welding, fasteners, adhesives and / or material intermediaries, such as in a manner that prevents galvanic corrosion.

[0030] In some implementations, the reinforcing insert can also include a flange attached between the upper flanges of the outer and inner sill members. The flange is attached to the exterior structure of the rocker assembly to support the tubular insert within the hollow space of the exterior structure. As shown in FIG. 8A, the reinforcing insert 220 includes an upper flange portion 270 that integrally extends upward from the crushable insert portion 268 and a lower flange portion 272 that integrally extends downward from the crushable insert portion 268. The upper and lower flange portions 270, 272 are attached between the upper and lower flanges 214a, 214b, 216a, 216b of the edges or flanges of the inner and outer sill members 214, 216 of the panels 212, 214, respectively, to secure the reinforcing insert 220 to the inner and outer sill members 214, 216. For example, the flange portions are spot welded between the first and second panels 214, 216, although alternative welding methods or different attachment means can be used, such as adhesives, mechanical fasteners, or combinations thereof. In other implementations, the integral flange of the reinforcing insert may be used to attach to a vehicle frame or other component part.

[0031] 7-8A, the reinforcing insert 220 is roll-formed from a metal sheet to provide the crushable insert portion 268 and the upper and lower flange portions 270, 272 as integral sections of the metal sheet to extend continuously longitudinally along the length of the reinforcing insert 220. The upper and lower flange portions 270, 272 of the reinforcing insert 220 are provided at the edges of the metal sheet. As shown in FIG. 8A, the wall sections of the crushable insert portion 268 include a common center wall 246, upper walls 252, 254, lower walls 256, 258, outer wall 248 and inner wall 250 that divide two adjacent tubular sections 214, 216. The crush channels 222 are roll-formed into the metal sheet at the upper walls 252, 254 and lower walls 256, 258. After welds are formed along the upper and lower walls to surround adjacent tubular sections 242, 244, an upper flange portion 270 extends upwardly from upper wall 254 and a lower flange portion 272 extends downwardly from lower wall 256.

[0032] 8A, an intermediate portion of the outer sill member 216 has an upper wall section 230 formed in a stepped shape that integrally interconnects with a generally planar and vertically oriented outermost wall section 232. The outermost wall section 232 extends downwardly to integrally interconnect with a generally planar lower wall section 234 that is angled slightly from a horizontal orientation. The stepped shape of the upper wall section 230 reduces the distance across the hollow interior 218 between the inner and outer sill members 214, 216 at the top of the inner sill member 214.

[0033] Similarly, for purposes of this disclosure, the terms "up," "down," "right," "left," "rear," "front," "vertical," "horizontal," "interior," "exterior," and their derivatives shall refer to the orientation shown in FIG. 1. It is understood, however, that various alternative orientations may be provided, unless expressly specified to the contrary. It is also to 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. Accordingly, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless expressly recited in the claims.

[0034] Variations and modifications to 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 terms described, rather than limiting. Many modifications and variations of the present disclosure are possible in light of the above teachings, and the disclosure may be practiced otherwise than as specifically described.

Claims

1. an outer sill member; an inner sill member attached longitudinally along the outer sill member to define a hollow space between the inner sill member and the outer sill member; a tubular insert disposed within and extending longitudinally along said hollow space, said tubular insert having upper and lower walls defining opposite sides of an interior volume of said tubular insert; 1. A vehicle rocker assembly comprising: the upper wall of the tubular insert has a first collapse channel extending longitudinally along the tubular insert, and the lower wall of the tubular insert has a second collapse channel extending longitudinally along the tubular insert; A vehicle rocker assembly, wherein the tubular insert is configured to initiate lateral deformation of the tubular insert at the crush channel in response to a side impact force at the outer sill member.

2. The vehicle rocker assembly of claim 1 , wherein said first and second collapse channels project into said interior volume of said tubular insert.

3. The vehicle rocker assembly of claim 1 , wherein the first and second collapse channels are disposed along the respective top and bottom walls on opposite sides of the interior volume.

4. The vehicle rocker assembly of claim 3 , wherein said upper and lower walls of said tubular insert are disposed in planar, parallel alignment with one another.

5. The tubular insert comprises: The vehicle rocker assembly of claim 1 comprising an outer tubular section and an inner tubular section integrally formed together and disposed laterally adjacent one another.

6. The vehicle rocker assembly of claim 5 , wherein said outer tubular section and said inner tubular section share a common central wall that extends perpendicularly between said upper and lower walls of said tubular insert.

7. The vehicle rocker assembly of claim 5 , wherein said outer tubular section includes an outer wall attached at said outer sill member.

8. The vehicle rocker assembly of claim 7 , wherein the first and second collapse channels are disposed along the respective upper and lower walls of the inner and outer tubular sections.

9. 8. The vehicle rocker assembly of claim 7, wherein the tubular insert comprises a metal sheet integrally formed having an outer tubular section, an inner tubular section and the first and second crush channels disposed therein.

10. a sill structure having an outer sill member attached along with an inner sill member; a reinforcing insert disposed in a hollow interior between the outer sill member and the inner sill member, the reinforcing insert comprising outer and inner tubular sections integrally formed together and disposed laterally adjacent one another; collapse control features integrally disposed on the upper and lower walls of the reinforcing insert and extending longitudinally along the length of the reinforcing insert; 1. A vehicle rocker assembly comprising: the collapse control feature comprises a first collapse channel disposed in the top wall of the reinforcing insert and a second collapse channel disposed in the bottom wall of the reinforcing insert; the first and second crush channels are symmetrically disposed throughout the interior volume of the reinforcing insert; 10. A vehicle rocker assembly, wherein the collapse control feature is configured to cause the reinforcing insert to deform laterally in an accordion-style collapse in response to a side impact force at the outer sill member.

11. The vehicle rocker assembly of claim 10 , wherein said outer tubular section and said inner tubular section share a common central wall of said reinforcing insert that extends perpendicularly between said top wall and said bottom wall of said reinforcing insert.

12. The reinforcing insert is The vehicle rocker assembly of claim 10 comprising a metal sheet integrally formed with said outer and inner tubular sections and said collapse control features disposed therein.

13. The vehicle rocker assembly of claim 10 , wherein said reinforcing insert is longitudinally extruded with said outer and inner tubular sections and said collapse control feature formed as a single, integral piece.

14. The vehicle rocker assembly of claim 10 , wherein the reinforcing insert is secured to the inner surface of the sill structure via at least one of a weld, fasteners, or adhesive.

15. an outer sill member; an inner sill member attached longitudinally along the outer sill member to define a hollow space between the inner sill member and the outer sill member; a tubular insert disposed within and extending longitudinally along said hollow space, the tubular insert including outer and inner tubular sections integrally formed together and disposed laterally adjacent one another and sharing a common central wall; 1. A vehicle rocker assembly comprising: at least one of the outer tubular section or the inner tubular section includes an upper collapsing channel disposed in an upper wall of the respective outer and inner tubular section and a lower collapsing channel disposed in a lower wall of the respective outer and inner tubular section; A vehicle rocker assembly, wherein the upper and lower crush channels extend longitudinally along the tubular insert and are configured to initiate lateral deformation of the tubular insert in response to a side impact force at the outer sill member.

16. The vehicle rocker assembly of claim 15 , wherein the upper and lower collapse channels are vertically aligned on the respective outer and inner tubular sections of the tubular insert.

17. 16. The vehicle rocker assembly of claim 15, wherein the upper and lower walls of the tubular insert are disposed in planar alignment with one another, and the outer tubular section and the inner tubular section share a common central wall extending perpendicularly between the upper and lower walls of the tubular insert.

18. an outer sill member; an inner sill member attached longitudinally along said outer sill member to define a hollow space along and between said inner and outer sill members; a tubular insert disposed within and extending longitudinally along said hollow space, said tubular insert having upper and lower walls defining opposite sides of an interior volume of said tubular insert; 1. A vehicle rocker assembly comprising: the upper wall of the tubular insert having a first collapse channel extending longitudinally along the tubular insert, and the lower wall of the tubular insert having a second collapse channel extending longitudinally along the tubular insert; 11. A vehicle rocker assembly, wherein the tubular insert is configured to laterally deform the tubular insert in the crush channel to provide an accordion-style lateral collapse in response to a side impact force at the outer sill member to at least partially absorb the side impact force.

19. The vehicle rocker assembly of claim 18 , wherein said first and second collapse channels project into said interior volume of said tubular insert.

20. 20. The vehicle rocker assembly of claim 18, wherein the first and second collapse channels are disposed along the respective top and bottom walls on opposite sides of the interior volume.

21. The tubular insert includes an outer tubular section and an inner tubular section sharing a common central wall extending between the upper wall and the lower wall of the tubular insert, The vehicle rocker assembly of claim 20 , wherein the first and second collapse channels are symmetrically disposed about the common central wall of the tubular insert.

22. The vehicle rocker assembly of claim 20 , wherein said first and second collapse channels are vertically aligned across said interior volume of said tubular insert.

23. The vehicle rocker assembly of claim 18 , wherein the first and second crush channels of the tubular insert are configured to simultaneously deform under the side impact force at the outer sill member.

24. 21. The vehicle rocker assembly of claim 20, wherein the upper and lower walls of the tubular insert are disposed in planar, parallel alignment with one another and spaced from the outer and inner sill members.

25. 20. The vehicle rocker assembly of claim 18, wherein the tubular insert comprises an outer tubular section and an inner tubular section integrally formed together and disposed laterally adjacent one another.

26. 26. The vehicle rocker assembly of claim 25, wherein said outer tubular section and said inner tubular section share a common central wall that extends perpendicularly between said upper and lower walls of said tubular insert.

27. a bracket mounted between the upper flanges of the outer and inner sill members; The vehicle rocker assembly of claim 18 , wherein the bracket is attached to the tubular insert and supports the tubular insert within the hollow space.

28. the tubular insert includes a flange mounted between the upper flanges of the outer and inner sill members; The vehicle rocker assembly of claim 18 , wherein said flange supports said tubular insert within said hollow space.

29. 20. The vehicle rocker assembly of claim 18, wherein the tubular insert is secured to an inner surface of the outer sill member or the inner sill member via at least one of a weld, fasteners, or adhesive.

30. the tubular insert comprises a metal sheet formed having an outer tubular section and an inner tubular section sharing a common central wall; The vehicle rocker assembly of claim 18 , wherein the outer and inner tubular sections are disposed laterally adjacent one another.

31. 20. The vehicle rocker assembly of claim 18, wherein said tubular insert is longitudinally extruded to have outer and inner tubular sections sharing a common wall integrally interconnecting said upper and lower walls of said tubular insert.

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