Vehicle cross member and floor assembly

Abstract

A floor assembly for a vehicle includes a floor panel having a metal plate and a pair of rocker members disposed longitudinally along sides of the floor panel. A cross member spans between the rocker members and includes a tubular beam having a cross-sectional shape that extends continuously along the length of the tubular beam. The cross-sectional shape of the cross member includes an enclosed tubular shape extending along its length and upper and lower wall portions each extending parallel to the tubular shape. Welds are disposed in the upper wall portion and extend through the lower wall portion to the metal plate of the floor panel to attach the cross member to the floor panel.

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 / 245,363, filed September 17, 2021, the contents of which are considered part of this application and incorporated herein by reference in their entirety. The present disclosure relates to floor structures and beams for vehicles, and more particularly to cross member structures and associated floor assemblies, subassemblies, and the like. [Background technology]

[0002] It is generally understood that vehicle frames and body structures are designed to receive and absorb certain levels of impact forces, such as to limit intrusion distance into the vehicle, in accordance with insurance and other regulatory and legal requirements. In battery storage for electric and hybrid electric vehicles, reducing side impact intrusion distance is desirable to maximize available battery storage volume, such as in a battery tray under the vehicle floor.

[0003] Side impacts on vehicles are commonly tested in side pole impact tests, which subject the vehicle to large side impact forces. The vehicle frame primarily absorbs these side impact forces with rocker sections that run longitudinally along the lower exterior portion of the vehicle frame. Summary of the Invention [Means for solving the problem]

[0004] One aspect of the present disclosure provides a vehicle floor assembly including a floor panel and a support beam disposed on an upper surface of the floor panel across the vehicle floor and extending across the upper surface of the floor panel. The support beam includes a cross-sectional shape that extends continuously along the linear length of the support beam. The cross-sectional shape of the support beam includes a lower wall portion that is welded to a metal plate of the floor panel to form a tubular shape that at least partially encloses a hollow area extending the linear length of the support beam. The weld may enclose the tubular shape formed by the cross-member alone or may enclose the tubular shape formed by the cross-member in combination with the floor panel. The enclosed tubular structure formed by welding the cross-member to the floor panel increases the stiffness and bending strength of the cross-member, allowing, for example, the cross-member to be formed from lighter, higher-gauge sheet metal material.

[0005] Implementations of the present disclosure may include one or more of the following optional features: In some examples, the support beam includes a metal plate formed with at least one tubular section extending along the linear length of the support beam. The metal plate of the support beam may be a martensitic steel having a tensile strength of at least 980 MPa, for example, a tensile strength of at least 1,500 MPa.

[0006] In some embodiments, the support beam includes a roll-formed metal plate having a pair of adjacent tubular members separated by a lower wall portion of the support beam. The pair of adjacent tubular members may be positioned horizontally adjacent to one another when spanning the vehicle floor. In some examples, the floor panel includes a ridge projecting upward from the planar extent of the floor panel, and the lower wall portion is welded to the ridge to position the pair of adjacent tubular members on either side of the ridge.

[0007] Another aspect of the present disclosure provides a vehicle floor assembly including a cross member. The vehicle floor assembly includes a floor panel having a metal plate and a pair of rocker members longitudinally disposed along sides of the floor panel. The cross member spans between the rocker members and includes a tubular beam having a cross-sectional shape that extends continuously along the length of the tubular beam. The cross-sectional shape of the cross member includes an enclosed tubular shape extending along its length and upper and lower wall portions that each extend alongside the tubular shape. Welds are disposed in the upper wall portion and extend through the lower wall portion to the metal plate of the floor panel to attach the cross member to the floor panel.

[0008] Embodiments of the present disclosure may include one or more of the following optional features: In some examples, a cross-member extends laterally across the vehicle floor to pass a load path between a pair of rocker members. In some embodiments, the cross-member includes a pair of tubular members divided by upper and lower wall portions. In some examples, the bottom surface of the cross-member contacts the upper surface of the tubular beam of metal plate along its length. The cross-member may be formed from metal plate having a tensile strength of at least 980 MPa, e.g., at least 1,500 MPa.

[0009] In some embodiments, the floor panel includes a ridge projecting upward from the planar extent of the floor panel, and the lower wall portion of the cross member is welded to the ridge to position a pair of adjacent tubular members of the cross member on either side of the ridge. In some examples, the metal plate of the floor panel includes martensitic steel with press-formed stiffening features.

[0010] In some examples, the vehicle floor assembly includes a second cross member mounted between and spanning a pair of rocker members at a longitudinally spaced distance from the other cross member, and the cross member may be used and configured to support a seat assembly mounted to the cross member.

[0011] The details of one or more embodiments of the present 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 explanation of the drawings]

[0012] [Figure 1] FIG. 1 is a side elevational view of a vehicle showing a floor assembly. [Figure 2] FIG. 2 is a top perspective view of the floor assembly shown in FIG. 1. [Figure 3] FIG. 2 is a plan view of the floor assembly shown in FIG. 1. [Figure 4] FIG. 2 is a side elevation view of the floor assembly of FIG. 1. [Figure 5] 5 is a cross-sectional view of the cross member taken along line VV in FIG. 4. [Figure 6] FIG. 10 is a cross-sectional view of an additional example of a cross member. [Figure 7] FIG. 10 is a cross-sectional view of another cross member. [Figure 8] 8 is a chart showing information related to the cross member of FIGS. 6 and 7. [Figure 9] FIG. 9 is a cross-sectional view of a further example cross member. [Figure 10] FIG. 10 is a cross-sectional view of a further example cross member. [Figure 11] FIG. 11 is a cross-sectional view of a further example cross member. [Figure 12] FIG. 12 is a cross-sectional view of a further example cross member. [Figure 13] FIG. 13 is a cross-sectional view of a further example cross member. DETAILED DESCRIPTION OF THE INVENTION

[0013] Like reference numbers refer to like parts throughout the drawings.

[0014] Referring now to the drawings and the illustrative examples depicted therein, a floor assembly 10 for a vehicle 100, as shown in FIG. 1, includes a floor panel 12 and a pair of rocker sections 14 disposed longitudinally along the sides of the floor panel 12. The floor assembly 10 or vehicle structure may also include press-formed features formed in the floor panel 12 between the longitudinal members or rocker sections 14. In an additional example, a central tunnel may protrude longitudinally along the center of the floor, such as to straddle or partially house vehicle drivetrain and exhaust system components in an internal combustion engine (ICE) vehicle. It is also contemplated that the central tunnel may house or partially enclose wiring harnesses, coolant lines, or electrical components, such as those associated with electric vehicles.

[0015] As shown in the example provided in FIG. 1 , vehicle 100 may include a battery tray 102 mounted generally interiorly from the outer sill of rocker section 14 and below floor panel 12 of floor assembly 10. Battery tray 102 encloses one or more batteries used at least in part to operate the propulsion system of vehicle 100, such as a main battery or battery module. Battery tray 102 may reside generally between front and rear wheels 104 of vehicle 100 to distribute the weight of the batteries and establish a low center of gravity for the vehicle. A vehicle, for purposes of this disclosure, may be any type of land motor vehicle, such as a car, truck, bus, van, sport utility vehicle, or the like, including those used for passenger transportation, freight transportation, or any other personal, government, or commercial purpose.

[0016] The floor assembly 10, as shown in Figures 2-4, includes at least one support beam, shown as cross member 20. In other examples, it is contemplated that additional cross members may be provided between rocker sections, with or without the cross member mounting configurations and structures shown in Figures 2-14. The cross member 20 is positioned on the upper surface of the floor panel 12, as shown laterally spanning the upper side of the vehicle floor panel 12, and extends above the upper surface of the floor panel 12. The cross member 20 includes a tubular beam having a cross-sectional shape that extends continuously along the length of the tubular beam, such that one or more cross-sectional shapes of tubular formations integral to the tubular beam are provided along the linear length of the cross member, as shown in Figure 2.

[0017] As shown in FIG. 3 , the cross member 20 is coupled to and spans the rocker sections 14 to define a lateral load path between the rocker sections 14 for transferring side impact loads or forces laterally across the floor panel 12. This reduces interior deformation due to a side impact and prevents, for example, impact interference with the battery tray. The rocker sections 14 are shown as an exemplary configuration and may be implemented as inner and outer sills, panels, or other longitudinal frame components or portions thereof. The cross member 20 may be coupled to the rocker sections directly or indirectly, such as through direct welds, adhesives, fasteners, and / or brackets. For example, the cross member may include a pair of mounting brackets attached between the ends of the tubular beam and the interior surface of the rocker sections. Such mounting brackets may be formed or press-formed in shapes for different configurations, such as for mounting along the sides or spanning the cross member.

[0018] As shown in FIGS. 2-6, the cross member 20 is positioned on the floor panel 12, with the bottom surface of the cross member 20 supported on the upper surface of the floor panel 12. The cross member 20 is attached to the metal plate of the floor panel 12 by welds 22 between the walls of the cross member 20 and the floor panel 12. The welds 22 enclose a tubular shape formed by the cross member 20 alone, as shown in FIG. 5, or by the cross member 120 in combination with the floor panel 112, as shown in FIG. 7. The enclosed tubular structure formed by the welds 22 of the cross member 20 to the floor panel 12 increases the stiffness and bending strength of the cross member, allowing, for example, the cross member to be formed from lighter, higher-gauge sheet metal material. Additionally, the welds of the cross member to the floor panel can provide a structural or support beam configured to attach a seat assembly to the vehicle floor.

[0019] As shown in FIG. 5 , the cross-sectional shape of the cross member 20 includes an overlap wall region 24 defined by an upper wall portion 26 closely positioned with a lower wall portion 28 along the length of the cross member 20. In the overlap region 24, the upper and lower wall portions 26, 28 have planar shapes and are positioned in abutting engagement with one another. It is understood that, due to manufacturing tolerances, direct contact may not be provided or maintained along the entire length. Prior to assembly with the floor panel 12, the overlap wall region 24 of the cross member 20 does not have welds between the upper and lower wall portions 26, 28. However, it is contemplated that in some instances, several welds may be intermittently positioned along the overlap region, so long as there is sufficient weld-free area to allow welds to be formed between the overlap region and the floor panel. Upon assembly with the floor panel 12, the overlap wall region 24 is welded to the metal plate of the floor panel 12, closing the tolerance gap between the upper and lower wall portions and enclosing one or more hollow areas adjacent to the overlap region. The weld joint 22 in the overlap region 24 may be formed by an intermittent or continuous laser weld or gas metal arc weld.

[0020] As also shown in FIG. 5 , the cross member 20 comprises a metal plate that is roll-formed to the cross-sectional shape shown, with the edges of the metal plate welded at an overlap joint 30. The cross-sectional shape has a pair of adjacent tubular sections or members, a front tubular section 32 and a rear tubular section 34, which are separated by an overlap region 24 formed by upper and lower wall portions 26, 28. The front tubular section 32 comprises a generally rectangular shape with a rear wall portion 36 integrally connected to the upper and lower wall portions 26, 28 that form the overlap region. The overlap region 24 transitions integrally rearward, with the upper wall portion 26 having an upwardly transitioning bend and the lower wall portion 28 having a downwardly transitioning bend, forming the front wall 38 of the rear tubular section 34. The cross-sectional shape of the rear tubular section 34 has a generally rectangular shape with the upper and rear wall portions 40, 42 angled rearward. As shown in Figure 5, the overlap joint 30 is formed in the top wall portion 32 of the rear tubular section 34 of the cross member 20. In additional examples, the overlap weld may be located in different areas of the cross-sectional shape. It is understood that additional examples may have tubular sections or members of various different shapes to accommodate desired mounting arrangements for different seat assemblies, interior counsel, etc.

[0021] Adjacent tubular sections 32, 34, as shown in Figures 5 and 6, are positioned horizontally adjacent to one another across the vehicle floor. The floor panel 12 includes a ridge 44 projecting upward from the planar extent of the floor panel 12, such that the lower wall portions 28 in the overlap region 24 of the cross member 20 contact the ridge 44, positioning the pair of adjacent tubular members 32, 34 on either side of the ridge 44 while simultaneously positioning the bottom wall portions 46, 48 of the front and rear tubular sections 32, 34 in connection with the planar portion of the floor panel 12 on the respective front and rear sides of the ridge 44. With the overlap region 24 in contact with the ridge 44, the weld fuses the upper wall portion 26, lower wall portion 28, and metal plates of the floor panel 12 together at the weld joint 22. The upper and lower wall portions 26, 28 are joined at the weld joint 22 to enclose the separate tubular shapes of the front and rear tubular members 32, 34 along the linear length of the cross member 22.

[0022] The floor panel 12 includes a steel plate with stamped stiffening features, as shown in FIG. 3. The stamped stiffening features include ridges 44 engaged by the cross-member welds 22, as well as additional features. The forward area of ​​the floor panel 12 includes a series of upwardly projecting lateral ribs 50 to stiffen a foot well in the forward area of ​​the floor panel 12. Another lateral ridge 52 is located rearward of the foot well and provides a structure for mounting the forward portion of the seat assembly. Two square recessed areas 54 are formed between the lateral ridges 52, 44 to provide space for seat assembly components, wiring harnesses, and air circulation below each seat assembly. A longitudinal ridge 56 is also formed between the forward ridge 52 and the cross-member 20 to provide additional longitudinal rigidity for supporting the seat assembly. A raised plus-shaped rib 58 and a surrounding raised pill-shaped rib 60 are provided behind the cross member to stiffen the floor panel in the rear seating or luggage area of ​​the vehicle. The metal plate of the floor panel may be martensitic steel, 2 mm thick, having a tensile strength of at least 980 MPa, and in some instances the floor panel may be divided into sections or separate floor pans.

[0023] In some examples, the vehicle floor assembly may include a second cross member mounted between and spanning a pair of rocker members at a longitudinally spaced distance from the other cross member. For example, a front ridge may include a cross member mounted therealong. In this case, the front and rear cross members may be used and configured to support the front and rear mounting locations of seat assemblies attached to the cross members.

[0024] As shown in FIG. 7, another example of a cross member 120 includes a lower wall portion 128 welded to the floor panel 112 at at least two locations to enclose a hollow tubular area defined between the cross member 120 and the floor panel 112. The cross-sectional shape of the cross member 120 shown in FIG. 7 includes four overlap regions 124 defined by the lower wall portion 128 positioned in close contact with the floor panel 112. In the overlap regions 124, the lower wall portion 128 and the floor panel 112 have planar shapes and are positioned in abutting engagement with each other. When the cross member 120 is assembled to the floor panel 112, the overlap regions 124 are welded to enclose a hollow area 125 adjacent to the overlap regions 124. The welds 122 in the overlap regions 124 can be formed by intermittent or continuous laser welding or gas metal arc welding.

[0025] 7, the cross member 120 includes a metal plate that is roll-formed into the open cross-sectional shape shown. This cross-sectional shape has three adjacent hat-shaped sections separated by overlap regions 124 formed between the lower wall portion 128 and the floor panel 112. The hat-shaped sections have various widths and heights to provide desired mounting surfaces for the resulting upper wall portion 140 of each tubular section. The cross member metal plate may be martensitic steel having a tensile strength of at least 980 MPa, such as at least 1,500 MPa, e.g., 1,700 MPa, as depicted in FIG. 9.

[0026] Another example of a floor assembly 210 is shown in FIG. 8 , where the cross-member has four tubular sections integrally formed from metal sheet that is bent or otherwise deformed, such as through roll forming or incremental press forming. The tubular sections of the cross-member in FIG. 8 are divided by a common center wall 262 that separates a pair of adjacent tubular sections 232, 234 positioned horizontally adjacent to one another (side-by-side) as they cross the vehicle floor 212. The metal sheets of the cross-member are roll-formed around the common center wall such that the sheets are bent in the same rotational direction around the center wall and welded to the center wall with their edges in contact with opposite ends of the center wall. Each of the pair of front and rear tubular sections 232, 234 is formed by bending the top and bottom walls vertically inward to provide a central overlap wall region 224. Each overlap wall region 224 is defined by an upper wall portion 226 closely positioned with a lower wall portion 228 along the length of the cross-member 220. At the overlap region, the upper and lower wall portions have planar shapes and are disposed in abutting engagement with one another, it being understood that direct contact may not be provided or maintained along the entire length due to manufacturing tolerances.

[0027] 8, the floor panel 212 includes two ridges 244 projecting upward from the planar extent of the floor panel 212, such that the lower wall portions 228 in each of the overlapping regions contact the ridges 244, positioning the pair of adjacent tubular sections 232, 234 on either side of the ridges 244. The tubular sections 232, 234 simultaneously connect the bottom wall portions of the front and rear tubular sections 232, 234 to portions of the floor panel on the respective front and rear sides of the ridges. With the overlapping regions in contact with the ridges 244, a weld 222 is formed (by intermittent or continuous laser welding or gas metal arc welding) to fuse the metal plates of the upper wall portion 226, the lower wall portion 228, and the floor panel 212 together at the weld joint 222. Joining the upper and lower wall portions 226, 228 with weld joint 222 encloses the distinct tubular shapes of front and rear tubular sections 232, 234 along the linear length of the cross member 220. Additionally, when assembled with the floor panel 212, an overlapping wall region 224 is welded to the metal plate of the floor panel 212, closing the tolerance gap between the upper and lower wall portions and enclosing the hollow area adjacent to the overlapping region. Forming the two weld joints 222 and the resulting four tubular sections shown in FIG. 8 significantly improves the strength of the cross member and floor panel, allowing the thickness of the cross member metal plate to be reduced, such as to about 0.96 mm ( FIG. 9 ), thereby reducing the weight of the cross member while maintaining structural performance. Additionally, the cross member metal plate, as shown in FIG. 9 , can be martensitic steel having a tensile strength of at least 980 MPa, e.g., at least 1,500 MPa, e.g., 1,700 MPa.

[0028] 10-14, additional examples of cross member and floor panel configurations having different overlap regions and weld joints are provided. Similar features to those described above are similarly numbered. As shown in FIG. 10, tubular sections 332, 334 are shown as substantially mirror images across weld joint 322 in the overlap region, except for overlap weld seam 330 at the top wall of rear tubular section 334. As shown in FIG. 11, cross member 420 includes two tubular sections 434, 435 aft of overlap region 424 welded to ridge 444. As shown in FIG. 12, floor panel 512 includes a rear stepped area 513 having a raised height from the floor panel toward ridge 544, such that rear tubular section 534 of cross member 520 has a shorter height below the overlap region, such that floor panel stepped area 513 supports rear tubular section 534. 13, the overlap region 624 may be attached to the two ridges 644 with two weld joints 622. Additionally, as shown in FIG. 14, the overlap region 724 is provided at an edge portion 764 of the metal plate of the cross member 720.

[0029] The cross members can be made from steel plates having a thickness between 0.8 mm and 1.4 mm, or between about 1 mm and 1.5 mm. The plates can also have a tensile strength of about 800 to 2000 MPa (i.e., about 120 to 290 ksi), such as at least 980 MPa or at least 1,500 MPa. In additional embodiments, the reinforcing beams can be made from different materials, including AHSS (Advanced High Strength Steel), and can be made from plates having a thickness between about 0.8 mm and 3.0 mm. Alternatively, the metal plates can be high-strength aluminum plates.

[0030] The cross member may also include mounting features at desired locations for mounting seat assemblies or other vehicle components or subassemblies. The mounting features may include holes or mounting features (e.g., SPAC nuts, riv nuts, etc.) at selected locations on the top wall to provide similar mounting locations.

[0031] The articles "a," "an," and "the" are intended to mean that one or more of the elements in the preceding description are present. The terms "comprise," "include," and "have" are intended to be inclusive and mean that additional elements other than the listed elements may be present. Furthermore, a numerical value, percentage, ratio, or other value is intended to include that value and other values ​​that are "about" or "approximately" the stated value as would be understood by one of ordinary skill in the art to be encompassed by embodiments of the present disclosure. Accordingly, stated values ​​should be interpreted broadly enough to encompass values ​​at least sufficiently close to the stated value to perform the desired function or achieve the desired result. The stated values ​​at least include expected variations in suitable manufacturing or production processes, and may include values ​​within 5%, 1%, 0.1%, or 0.01% of the stated value.

[0032] Also, for purposes of this disclosure, the terms "approximately," "about," and "substantially" as used herein refer to an amount close to the stated amount that still performs the desired function or still achieves the desired result. For example, the terms "approximately," "about," and "substantially" can refer to an amount within less than 5%, less than 1%, less than 0.1%, and less than 0.01% of the stated amount. Furthermore, 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," "interior," and "exterior," and their derivatives, are intended to refer to the directions shown in FIG. 1 . However, it should be understood that various alternative orientations may be provided unless expressly specified to the contrary. It should also be understood that the specific devices 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 related to the embodiments disclosed herein are not to be considered limiting unless the claims expressly state otherwise.

[0033] Variations and modifications to the specifically described embodiments may be made without departing from the principles of the invention, which is intended to be limited only by the appended claims as interpreted in accordance with the principles of patent law. The present disclosure has been described in an illustrative manner. It will be understood that the terminology used is intended to be in the nature of descriptive language, rather than limiting. Many modifications and variations of the present disclosure are possible in light of the above teachings. The present disclosure may be practiced otherwise than as specifically described.

Claims

1. A floor panel including a metal plate, the floor panel including a raised portion protruding upward from a planar extent of the floor panel; a support beam disposed on the upper surface of the metal plate and extending across the upper surface of the metal plate; 1. A vehicle floor assembly comprising: the support beam has a cross-sectional shape that extends continuously along a linear length of the support beam; the cross-sectional shape of the support beam includes a lower wall portion welded to the raised portion of the metal plate of the floor panel to form a tubular shape at least partially enclosing a hollow area extending the linear length of the support beam; the support beam comprises a roll-formed metal plate having a pair of adjacent tubular members separated by the bottom wall portion of the support beam; the lower wall portion is attached to the raised portion such that the pair of adjacent tubular members are disposed on opposite sides of the raised portion; Vehicle floor assembly.

2. A vehicle floor assembly as described in claim 1, wherein the metal plate of the support beam comprises martensitic steel having a tensile strength of at least 980 MPa.

3. The vehicle floor assembly of claim 1 , wherein the support beam is configured to extend laterally across the vehicle floor.

4. 2. The vehicle floor assembly of claim 1, further comprising a pair of rocker sections extending longitudinally along the outer edge of the floor panel, the support beam extending laterally across the vehicle floor between the pair of rocker sections, the support beam defining a lateral load path between the pair of rocker sections.

5. The vehicle floor assembly of claim 4 , wherein the pair of adjacent tubular members are positioned horizontally adjacent one another when spanning the vehicle floor.

6. 10. The vehicle floor assembly of claim 1, wherein the support beams comprise martensitic steel plates having a tensile strength of at least 1,500 MPa.

7. a floor panel including a metal plate; a pair of rocker members arranged longitudinally along the sides of the floor panel; a cross member coupled to the pair of rocker members and spanning between the pair of rocker members, the cross member comprising a tubular beam having a cross-sectional shape that extends continuously along the length of the tubular beam; 1. A vehicle floor assembly comprising: a cross-sectional shape of the cross member including an enclosed tubular shape extending along the length; the cross-sectional shape of the cross member includes upper and lower wall portions each extending parallel to the tubular shape; a weld is disposed in the upper wall portion and extends through the lower wall portion to the metal plate of the floor panel for attaching the cross member to the floor panel; the cross member comprises a pair of tubular members divided by the upper and lower wall portions; The floor panel includes a protrusion that protrudes upward from a planar extent of the floor panel, the lower wall portion is attached to the raised portion so as to position the pair of adjacent tubular members on either side of the raised portion; Vehicle floor assembly.

8. 8. The vehicle floor assembly of claim 7, wherein the cross member comprises martensitic steel having a tensile strength of at least 980 MPa.

9. 9. The vehicle floor assembly of claim 8, wherein the cross member extends laterally across the vehicle floor to provide a load path between the pair of rocker members.

10. 8. The vehicle floor assembly of claim 7, wherein the cross member comprises martensitic steel plate having a tensile strength of at least 1,500 MPa.

11. 8. The vehicle floor assembly of claim 7, wherein a bottom surface of said cross member contacts an upper surface of said floor panel along said length of said tubular beam.

12. The cross member is a first cross member, a second cross member mounted between and spanning the pair of rocker members at a longitudinally spaced distance from the first cross member; a seat assembly coupled to and supported by the first and second cross members; The vehicle floor assembly of claim 7 further comprising:

13. a floor panel including a metal plate; a support beam disposed on an upper surface of the metal plate and extending across the upper surface of the metal plate, the support beam comprising a tubular beam having a cross-sectional shape that extends continuously along its length; 1. A vehicle floor assembly comprising: the cross-sectional shape of the support beam includes upper and lower wall portions each extending parallel to the tubular shape; a weld disposed in the upper wall portion and extending through the lower wall portion to the metal plate of the floor panel for attaching the support beam to the floor panel; the support beam comprising a pair of adjacent tubular members divided by the upper and lower wall portions; The metal plate includes a protrusion that protrudes upward from the planar extent of the floor panel, the cross-sectional shape of the support beam includes a lower wall portion attached to the raised portion of the metal plate so as to position the pair of adjacent tubular members on either side of the raised portion; Vehicle floor assembly.

14. a pair of rocker members arranged longitudinally along the sides of the floor panel; 14. The vehicle floor assembly of claim 13, wherein the support beam is coupled between and spans the pair of rocker members.

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