Rocker assemblies, rocker inserts, and vehicle beam components for vehicles.

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 and priority under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application No. 63 / 363,785, filed on April 28, 2022, the disclosure of which is hereby incorporated by reference in its entirety and made a part of this application.

[0002] This disclosure relates to structural members and beams, and more particularly to vehicle components for use as structural and reinforcement beams in, for example, locker assemblies, battery trays, and other vehicle frame structures.

Background Art

[0003] Vehicle frames and body structures are designed to support the vehicle and to receive and absorb a certain level of impact force so as to prevent intrusion distances into the vehicle in accordance with insurance requirements and other regulatory and legal requirements. Side impacts to a vehicle are generally tested in a side pole impact test, which transmits a large side impact force to the vehicle. The vehicle frame mainly absorbs these side impacts through a rocker section that runs longitudinally between the front and rear wheels along the lower outboard portion of the vehicle frame.

[0004] In electric and hybrid electric vehicles, when a battery tray is incorporated in the lateral in - vehicle area between opposing rocker sections, it is desirable to direct side impact forces from the battery tray towards the vehicle floor cross - member. For example, it is generally known to increase the rigidity of the vehicle sill assembly, such as by adding a rocker insert within the vehicle sill assembly.

Summary of the Invention

Means for Solving the Problems

[0005] This disclosure provides a vehicle structural component, such as a rocker component, which 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 may be a vehicle rocker assembly, which includes stiffening members positioned within the hollow interior of the rocker assembly. The stiffening members have a top wall, a bottom wall, and side walls, forming, for example, a C-shaped cross-section. The rocker assembly also includes a second stiffening member, each having multiple wall sections, each including 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 position spaced along the length of the rocker assembly from the upper portion. These two types of stiffening members work together in lateral impact energy management, for example, to increase the lateral bending strength of the rocker insert, when subjected to an in-vehicle lateral impact force, the top and bottom walls of the first stiffening member are supported by the second stiffening member in a generally planar, parallel alignment. Multiple wall sections of the second stiffening member are also configured to align with lateral impact loads to give the rocker section high crush resistance and rigidity. The combined properties of the cooperating stiffening members provide enhanced resistance to intrusion as a result of lateral impact along the length of the rocker assembly.

[0006] According to one aspect of the present disclosure, a vehicle rocker assembly includes one or more sill outers or sill inners 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 side walls. The rocker insert also includes a second stiffening member having a plurality of wall sections, each having an upper portion that engages with the top wall and a lower portion that engages with the bottom wall at a distance from the upper portion along the length of the rocker insert. The top and bottom walls of the first stiffening member are configured to be supported by the second stiffening member when subjected to an in-vehicle lateral impact force in order to increase the lateral bending strength of the rocker insert.

[0007] According to another aspect of the present disclosure, a rocker insert is provided which is configured to be positioned within an elongated hollow interior defined by one or more of the in-vehicle wall portions of a sill inner and the out-vehicle wall portions of a sill outer. The rocker insert includes a first stiffening member having a top wall, a bottom wall, and side walls. The rocker insert also includes a second stiffening member which includes a plurality of wall sections, each having an upper portion that engages with the top wall and a lower portion that engages with the bottom wall at a position spaced apart from the upper portion along the length of the rocker insert. The top and bottom walls of the first stiffening member are configured to be supported by the second stiffening member when subjected to an in-vehicle lateral impact force in order to increase the lateral bending strength of the rocker insert.

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

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

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

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

[0012] In some examples, the flange portion of the top wall extends from the rest of the top wall at an angle of approximately 80 to 100 degrees.

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

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

[0015] In some examples, one or more of the top wall flanges and bottom wall flanges 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] Details of one or more implementations of this disclosure are described in the accompanying drawings and the following description. Other embodiments, advantages, purposes, and features will become apparent upon further consideration of the following specification in conjunction with the drawings. [Brief explanation of the drawing]

[0018] [Figure 1] This is a schematic side view of the vehicle showing the rocker assembly and battery tray housing. [Figure 2] This is a schematic perspective view of the vehicle showing the rocker assembly and other structural components. [Figure 3] This is a cross-sectional view of an example of a vehicle rocker assembly including a rocker insert. [Figure 4] Figure 3 is a perspective view of the rocker insert shown. [Figure 5] Figure 4 is a side view of the rocker insert shown. [Figure 6] Figure 4 is a top view of the rocker insert. [Figure 7] Figure 4 is an end view of the rocker insert. [Figure 8A] Figure 4 is a side view of the opposite side of the rocker insert shown. [Figure 8B] This is an enlarged view of the section shown in Figure 8A. [Figure 9A] Figure 4 is a perspective view of the second stiffening member of the rocker insert. [Figure 9B] It is an enlarged view of the section shown in FIG. 9A. [Figure 10] It is a perspective view of another example of the locker insert. [Figure 11] It is an enlarged side view of the locker insert shown in FIG. 10. [Figure 12] It is an enlarged perspective view of the second stiffening member of the locker insert shown in FIG. 10. [Figure 13] It is a perspective view of another example of the locker insert. <000009,5>It is an enlarged side view of the locker insert shown in FIG. 13. [Figure 15] It is an enlarged perspective view of the second stiffening member of the locker insert shown in FIG. 13. [Figure 16] It is a perspective view of another example of the locker insert. [Figure 17] It is an enlarged side view of the locker insert shown in FIG. 16. [Figure 18] It is an enlarged perspective view of the second stiffening member of the locker insert shown in FIG, 16. [[ID=,31]] [Figure 19] [[ID=3,2]]It is a perspective view of another example of the locker insert. [Figure 20] It is an enlarged side view of the locker insert shown in FIG. 19. X [Figure 21] It is an enlarged perspective view of the second stiffening member of the locker insert shown in FIG. 19. [Figure 22] It is a perspective view of another example of the locker insert. [Figure 23] It is an enlarged side view of the locker insert shown in FIG. 22. [Figure 24] It is an enlarged perspective view of the second stiffening member of the locker insert shown in FIG. 22. [[ID=,49]] [Figure 25] It is a perspective view of another example of the locker insert. [Figure 26] It is an enlarged side view of the locker insert shown in FIG. 25. [Figure 27] It is an enlarged perspective view of the second stiffening member of the locker insert shown in FIG. 25. ] [Figure 28] A perspective view of another example of a rocker insert. [Figure 29] Figure 28 is an enlarged side view of the rocker insert shown. [Figure 30] Figure 28 is a perspective view of the second stiffening member of the rocker insert. [Figure 31] A perspective view of another example of a rocker insert. [Figure 32] Figure 31 is an end view of the rocker insert. [Figure 33] Figure 31 is an exploded perspective view of the second stiffening member of the rocker insert. [Figure 34] A perspective view of another example of a rocker insert. [Figure 35] Figure 34 is an end view of the rocker insert shown. [Figure 36] Figure 34 is an exploded perspective view of the second stiffening member of the rocker insert shown. [Figure 37] A perspective view of another example of a rocker insert. [Figure 38] Figure 37 is an end view of the rocker insert shown. [Figure 39] Figure 37 is an exploded perspective view of the second stiffening member of the rocker insert shown. [Figure 40] A perspective view of another example of a rocker insert. [Figure 41] Figure 40 is an end view of the rocker insert shown. [Figure 42] Figure 40 is an exploded perspective view of the second stiffening member of the rocker insert shown. [Modes for carrying out the invention]

[0019] Similar reference numbers indicate the same parts throughout the drawing.

[0020] Referencing the drawings and the embodiments described herein, beam components for a vehicle 100 are provided, such as those for a body structure or frame 102, as shown in Figures 1 and 2. The vehicle frame 102 and related components may have various designs and configurations, such as for different styles and types of vehicles. For example, as shown in Figures 1 and 2, the vehicle frame 102 has various structural components, among other structural components, including B-pillars, hinge pillars, floor cross members 106, roof bows, and headers, which support the body of the vehicle and protect occupants, engine components, and sensitive electronics from damage in the event of a collision. In some examples, the vehicle 100 may be powered by a propulsion system that uses batteries, such as batteries or battery modules, which may be supported in battery trays 104, which are generally located 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 lateral members, or other structural components that may benefit from the impact energy management characteristics provided and disclosed herein. Vehicle rocker components include one or more sill panels, such as a sill inner panel 12 and a sill outer panel 14 mounted together around an internal area 16, where the terms “inner” and “outer” refer to directions on the vehicle that are inward or oriented in the vehicle and outward or oriented outwards, as oriented in Figure 1. As shown in Figures 2 and 3, an example of a vehicle rocker assembly 10 includes reinforcing inserts positioned in the internal area 16 to form a multi-tubular rocker structure. The rocker assembly 10 shown in Figure 2 is positioned alongside the outer section of a battery tray 104, where a floor cross member 106 is mounted to the vehicle rocker assembly 10 so as to straddle the battery tray 104 laterally. Thus, vehicle components in additional implementation forms may also or alternatively be provided as battery tray frame components, such as side wall sections oriented longitudinally of the battery tray.

[0022] When designing a vehicle rocker assembly having the rocker inserts disclosed herein, it is possible to reduce the external dimensions of the vehicle rocker assembly and lower the overall weight of the vehicle rocker assembly while meeting the required impact and load conditions. The rocker inserts may extend over a partial section of the vehicle rocker assembly or over the entire length of the rocker assembly, thereby extending beyond the rocker assembly into adjacent components and reinforcing those adjacent components as well. The rocker inserts disclosed herein may constitute an entire vehicle component or may be bonded to an additional reinforcement or part of a vehicle component, such as a desired section of the vehicle component. Furthermore, in some examples, the rocker assembly may be embodied as a subassembly or as part of a corresponding vehicle component, such as a structural component or a battery tray component, and as such, may be designed to withstand various impact forces and support and endure different load conditions.

[0023] Furthermore, the rocker inserts disclosed herein may be formed from one or more sheet material pieces, such as by roll forming a metal sheet, thereby providing a structure with relatively high strength (against shear and axial loads) and low weight compared to a typical rocker panel, thereby allowing, for example, the sill panel (if provided) of the corresponding vehicle component to use less material, occupy less packaging space, and have greater flexibility in external design. The cross-sectional shapes of different examples of vehicle components and rocker inserts may include various shapes and thicknesses for desired applications of the vehicle components. Furthermore, some embodiments of the rocker inserts may include aluminum extrusions combined with metal sheet material, such as those shown in Figure 28.

[0024] Unless otherwise specified, additional implementations of rocker components may have orientations opposite to those shown and described, such as a sill panel identified as an inner panel being used as an outer panel, and a sill panel identified as an outer panel being used as an inner panel. The cross-sectional shapes of the inner and outer panels may vary along the rocker, for example, by widening outward at the ends.

[0025] Referring here to the vehicle rocker assembly 10 shown in Figure 3, the first sill panel 12 and the second sill panel 14 are mounted together to surround the hollow internal space 16 between the sill panels 12 and 14. The vehicle rocker assembly 10 shown in Figure 3 is embodied as a vehicle rocker component. Therefore, the first sill panel 12 is sometimes called the sill inner panel of the rocker component. The first sill panel 12 has an upper flange 18 and a lower flange 20 extending along the upper and lower edges of the inner panel, respectively. The first sill panel 12 protrudes inward from the upper and lower flanges 18 and 20, forming an outward-facing concave structure. The second sill panel 14, sometimes called the sill outer panel of the rocker component, has a C-shaped cross-section with flanges 22 and 24, which are similarly sometimes called an upper flange 22 and a lower flange 24. The upper flanges 18 and 22 and lower flanges 20 and 24 of the inner and outer sill panels 12 and 14 are mounted to each other by welding or the like with their concave structures facing each other. The upper and lower flanges 18, 20, 22, and 24 of the sill panels 12 and 14 shown in Figure 3 extend continuously along the longitudinal edge of the rocker component, although the flanges may be cut off in selected areas to facilitate frame mounting or to reduce weight.

[0026] As further shown in Figure 3, the inner and outer sill panels 12, 14 are joined together to define a hollow internal 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 to contact and fit together in a generally continuous manner along the length of the component. The upper and lower flanges 18, 20, 22, 24 may be joined together by welding, preferably spot welding. However, alternative welding methods or joining means, such as adhesives or fasteners, may be used in addition to or instead of spot welding in different mounting configurations of the rocker component.

[0027] The first sill panel 12, i.e., the inner panel of the vehicle rocker assembly 10, has a substantially planar inner wall 26 or interior wall portion. The inner wall 26 is integrally interconnected with corner transitions to the upper wall 28 and lower wall 30 at their respective upper and lower ends. The corner transitions are approximately 90 degrees between the inner wall 26 and the upper and lower walls 28, 30. The corner transitions are also defined by longitudinal bending of the sheet material forming the first sill panel 12, such as a metal sheet (e.g., high-strength steel sheet or aluminum sheet). Similarly, the upper and lower walls 28, 30 each have corner transitions approximately 90 degrees to the upper flange 18 and lower flange 20, respectively. The corner transitions are also defined by longitudinal bending of the sheet material of the first sill panel 12, such as being formed by a roll forming process. As similarly shown in Figure 3, the upper and lower flanges 18, 20 are substantially planar and oriented in alignment parallel to the planar spread of the inner wall 26. The upper and lower walls 28, 30 of the first sill panel 12 are also substantially planar and substantially parallel to each other, as shown in Figure 3, although in additional examples they may be at a slight angle to each other. The corner transitions may also have angles larger or smaller 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 Figure 3, the second sill panel 14 or outer panel of the vehicle rocker assembly 10 is substantially planar and has an outer wall 32 or vehicle exterior wall portion that integrally interconnects with the upper wall 34 and lower wall 36 at their respective upper and lower ends. The approximately 80-degree corner transition between the outer wall 32 and the upper and lower walls 34, 36 is defined by a longitudinal bend in the plate material forming the second sill panel 14. The plate material may be the same as or different from that of 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, which are also defined by a longitudinal bend in the plate material of the second sill panel 14. Here too, the corner transitions between the upper and lower walls 34, 36 and the upper and lower flanges 22, 24 and the outer wall 32 may have angles that are larger or smaller than those shown in Figure 4, such as between approximately 40 and 120 degrees, between 70 and 100 degrees, between 80 and 95 degrees, or between 82 and 92 degrees.

[0029] As shown in Figure 3, the upper and lower flanges 22, 24 are substantially planar and oriented in alignment with the planar spread of the outer wall 32. The upper and lower walls 34, 36 of the second sill panel 14 are also substantially planar, but are slightly angled from being perpendicular to the outer wall 32 and flanges 22, 24. With the flanges 18, 20, 22, 24 of panels 12, 14 installed together, their walls define a substantially hexagonal cross-sectional shape, however, examples of additional rocker inserts may have various alternative cross-sectional shapes (e.g., substantially rectangular shapes) and different wall configurations (e.g., parts of the inner or outer wall that are not vertically oriented) for the corresponding vehicle design. Furthermore, in other examples, the outer sill and inner sill may include different configurations, including, but not limited to, having inwardly or outwardly projecting reinforcing rib portions configured so that the outer sill provides additional rigidity and lateral impact support.

[0030] As further shown in Figures 3 and 4, the vehicle rocker assembly 10 includes a rocker insert 40 positioned within an elongated hollow interior 16. The rocker assembly 10 includes a first stiffening member 41 comprising 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 positioned approximately 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 of 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 of 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 surfaces, but various other embodiments are conceivable, including corrugations 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 that extend diagonally from the top wall 80 and the bottom wall 82. The angle between the flange and the top wall or bottom wall 82 may be approximately 90 degrees, but various other angles are conceivable, including but not limited to angles in the range of 25–125 degrees, 35–115 degrees, 45–105 degrees, 60–100 degrees, 80–100 degrees, and 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, sill outer, or other vehicle component. In one example, one or more of the top wall flange portions and bottom wall flange portions are coupled to the sill inner. For example, the rocker insert can replace a conventional sill outer so that a separate sill outer is not required. In another example, one or more of the top wall flange portions and bottom wall flange portions are coupled to the sill outer. In this case, the rocker insert can replace a conventional sill inner so that a separate sill inner is not required. In one example, the coupling of one or more flange portions to the sill inner or sill outer is a direct coupling performed by welding. However, various other configurations are conceivable, including but not limited to indirect couplings in which another component is positioned between the flange portion and the sill inner or sill outer.

[0033] Furthermore, in the illustrated example, the side wall 84 curves outward from both the top wall 80 and the bottom wall 82, then curves inward toward the channel and merges in the recess 90. In some examples, the recess 90 is curved to have a generally U-shape, forming a stiffening channel along the side wall 84. The depth and extent of the stiffening channel can be modified based on the requirements for the configuration, the hardness, ductility, and thickness of the sheet material, among other considerations. In additional examples, additional stiffening channels may be formed in the side wall, or the stiffening channels may be omitted or have a different shape. In some examples, without departing from the spirit of the invention, one or more of the top wall 80 or bottom wall 82 may include notches for accommodating other vehicle components.

[0034] Further reference to the examples shown in Figures 3 and 4, it is conceivable that one of the flange portions 88 of the side wall and / or top wall and bottom wall 82 may be coupled to either the inner sill or the outer sill to support the rocker insert 40 within the elongated hollow interior 16. Here again, this coupling may be by welding, but other coupling methods, including but not limited to the use of fasteners and adhesives, are also conceivable. In one example, the side wall is coupled to the inner sill. In another example, the side wall is coupled to the outer sill. In yet another example, the flange portion 88 of the top wall and / or bottom wall 82 is coupled to the outer sill. In yet another example, the flange portion 88 of the top wall and / or bottom wall 82 is coupled to the inner sill.

[0035] Referring further to the examples shown in Figures 3 and 4, the rocker insert 40 also includes a second stiffening member 42. The second stiffening member 42 is at least partially located within the channel formed by the top wall 80, bottom wall 82, and side walls 84 of the first stiffening member 41. The stiffening member 42 includes at least one wall portion 46 defining a front edge 48, a rear 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 arranged parallel to each other along the length of the rocker insert 40. In one example, the front edge 48 and the rear edge 50 are located at different positions along the length of the rocker insert 40. The second stiffening member 42 may be located along the entire length of the rocker insert 40, or, in additional examples, along a portion of the length of the rocker insert 40, for example, 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 mounted within the channel of the first stiffening member of the rocker insert, and the first stiffening member of the rocker insert 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 roll-formed or bent into a desired shape. Alternatively, at least one wall portion 46 may be composed of another material having desired strength requirements and / or non-coiled steel or aluminum. Furthermore, at least one wall portion 46 may be formed by other means.

[0037] In some examples, the stiffening member 42 includes a plurality of wall portions 46 connected to each other in the longitudinal direction of the vehicle, each wall portion 46 having a front edge 48, a rear edge 50, a first side edge 52, and a second side edge 54 opposite to the first side edge 52. Furthermore, the front edge 48 and rear edge 50 of each of the plurality of wall portions 46 are positioned at different locations along the length of the rocker insert 40. Furthermore, the second stiffening portion 42 includes a second wall portion 46 having a front edge 48, a rear edge 50, a first side edge 52, and a second side edge 54 opposite to the first side edge 52, which is connected to the first wall portion 46 such that the front edge 48 and rear edge 50 of the second wall portion 46 are positioned at the same forward and rearward positions as the front edge 48 and rear edge 50 of the second wall portion 46. In one example, the upper wall portion 62 of the first wall portion 46 is joined to the lower wall portion 64 of the second wall portion 46, but various other configurations are possible. In one example, the first wall portion 46 and the second wall portion 46 are joined by welding, but various other joining methods are possible, including but not limited to the use of fasteners and / or adhesives. In one example, the upper wall portion 62 of each of the multiple wall sections engages at a first position along the length of the rocker insert, and the lower wall portion 64 engages at a second position along the length of the rocker insert 40. In some examples, the distance between the first position and the second position is substantially the same for each of the multiple wall sections along the rocker insert 40. In other examples, the distance between the first position and the second position is variable for each of the multiple wall sections along the rocker insert 40.

[0038] Referring further to the examples shown in Figures 3 and 4, the cross-sectional shape of the second stiffening portion 42 includes a general corrugated shape having a series of upper wall portions extending parallel to each other. 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. Multiple wall sections of the second stiffening member 42 extend substantially perpendicularly to the side wall 86 of the first stiffening member 41 and are aligned or substantially aligned with the in-cabin lateral impact force on the vehicle. In other words, the multiple wall sections extend roughly perpendicularly from the side wall 86 to the rest 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 portion 52 and the second side edge portion 54 and is configured to bear a lateral load path between the inner wall portion and the outer wall portion. In other words, the upper wall portion 62 of the second stiffening portion 42 extends at least partially between the sill inner and sill outer, if included. As shown in the example in Figures 3 and 4, the lower wall portion 64 of the second stiffening portion 42 also extends between the first side edge portion 52 and the second side edge portion 54 and is configured to bear a lateral load path between the outer wall portions.

[0040] The lateral direction of the vehicle generally extends along the entire width dimension of the vehicle. In contrast, the longitudinal direction of the vehicle generally extends along the length dimension of the vehicle. In some examples, the upper wall portion 62 may be generally positioned in a horizontal plane. The upper wall portion 62 of the second stiffening portion 42 is configured to be oriented to be roughly aligned with the expected lateral impact to the side of the vehicle so as 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 extend across the entire surface or be positioned only on a portion of the surface. The upper wall portion 62 and the lower wall portion 64 may be of any desired shape and side profile, 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. Furthermore, the upper wall portion 62 and the lower wall portion 64 may have the same shape, or they may have different shapes. In addition, the upper wall portion 62 and / or the lower wall portion 64 may have a single repeating shape, an alternating shape, or any pattern of wall shapes or other intended arrangements.

[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 conceivable 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 each other, such that the height of the upper wall portion 62 is greater than the depth of the lower wall portion 64, or vice versa. Furthermore, it is conceivable that the height of the upper wall portion 62 may remain constant along the second stiffening member 42. However, it is also conceivable that the height of the upper wall portion 62 may be variable along the second stiffening member 42. Similarly, it is conceivable that the depth of the lower wall portion 64 may remain constant along the second stiffening member 42. However, it is also conceivable 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 as the width of the lower wall portion 64. However, 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 each other, such that the width of the upper wall portion 62 is greater than the width of the lower wall portion 64, or the width of the lower wall portion 64 is greater than the width of the upper wall portion 62. Furthermore, the width of the upper wall portion 62 may remain constant along the length of the second stiffening member 42. However, the width of the upper wall portion 62 may be variable along the second stiffening member 42. Similarly, the width of the lower wall portion 64 may remain constant along the length of the second stiffening member 42. However, 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 to 1.5 mm. In other examples, the lower wall portion 64 has a width of approximately 0.8 to 1.3 mm. In yet another example, the lower wall portion 64 has a width of approximately 0.9 to 1.1 mm. In one example, the lower wall portion 64 has a width of approximately 0.9 mm. In yet another example, the lower wall portion 64 has a width of approximately 1.1 mm. However, various other widths for the lower wall portion 64 are also considered.

[0044] In some examples, multiple wall sections 46 are spaced apart from each other by 100 mm or less. In other examples, multiple wall sections 46 are spaced apart from each other by 75 mm or less. In still other examples, multiple wall sections 46 are spaced apart from each other by 50 mm or less.

[0045] In the examples shown in Figures 3 and 4, the cross-sectional shape begins with an upper wall portion 62, which is a generally flat surface. Next, the second stiffening member 42 changes into an angled portion 68 that extends diagonally downward before reaching another generally flat surface, the lower wall portion 64. Another angled portion 68 extends upward from the flat surface of the lower wall portion 64 toward the second upper wall portion 62. In the illustrated examples, the angled portion 68 extends at an angle of approximately 45 degrees, but other angles of 15 to 105 degrees are considered. The angled portion 68 provides a shape such that the distance between the first lower wall portion 64 and the second lower wall portion 64 is greater than the length of the upper wall portion 62. Similarly, the distance between the first upper wall portion 62 and the second upper wall portion 62 is greater than the length of the lower wall portion. As shown in the examples in Figures 3 and 4, this shape is then repeated in a pattern over the entire length. However, various other shapes are conceivable. Furthermore, 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 wall portion 62 / lower wall portion 64 and near the reinforcing ribs 70 is curved, but various other configurations are conceivable, including transitions with sharper angles.

[0046] Furthermore, as described above, the upper wall portion 62 and lower wall portion 64 of the second stiffening member 42 may be joined to the top wall 80 and bottom wall 82, respectively. Typically, this joining is done by welding, but other processes including but not limited to fasteners or adhesives are also conceivable. 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 in-vehicle lateral impact forces in order to increase the lateral bending strength of the rocker insert. In other words, in the configuration described, the integration of the first stiffening member 41 and the second stiffening member 42 provides a cooperative structural effect that increases the lateral bending strength of the rocker insert 40, which leads to a lower risk of failure or buckling threshold of the rocker insert when subjected to lateral impact forces, and this may in turn increase battery package space, the resulting vehicle range, and the overall safety of the vehicle.

[0047] Next, referring to the example shown in Figures 10-12, the rocker assembly 110 includes, but is not limited to, a sill outer, a sill inner, and a rocker insert 140 positioned within the elongated interior of the sill structure, and includes features similar to those described above with respect to the rocker assembly 10 shown in Figures 1-9B. The rocker insert 140 similarly includes a first stiffening member 141 that, together with the rocker insert 140, defines a top wall 180, a bottom wall 182, and a side wall 184 integrally connecting the top wall and the bottom wall. The 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 positioned at different locations along the length of the rocker insert 140. However, as illustrated in the example shown in Figures 10-12, the angled portion 168 of the second stiffening member 142 extends at a smaller angle than in the example shown in Figures 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, in the range of 95 to 105 degrees, such that the distance between the first upper wall portion 162 and the second upper wall portion 162 is slightly greater than the width of the lower wall portion 164. Similarly, as shown in Figure 11, the distance between the first lower wall portion 164 and the second lower wall portion 164 is slightly greater than the width of the upper wall portion 162.

[0048] Referring to the example shown in Figures 13-15, the rocker assembly 210 includes, but is not limited to, a sill outer, a sill inner, and a rocker insert 240 positioned within the elongated interior of the sill structure, and includes features similar to those described above with respect to the rocker assembly 10 shown in Figures 1-9B. The rocker insert 240 similarly includes a first stiffening member 241 that, together with the rocker insert 240, defines a top wall 280, a bottom wall 282, and a side wall 284 integrally connecting the top wall and the bottom wall. The 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 positioned at different locations along the length of the rocker insert 240. However, as shown in the examples in Figures 10-12, the angled portion 268 of the second stiffening member 242 extends at an angle of approximately 90 degrees before reaching the reinforcing rib 270, and then continues to extend almost perpendicular to the upper wall portion 262 and the lower wall portion 264. Thus, the distance between the first upper wall portion 262 and the second upper wall portion 262 is approximately equal to the width of the lower wall portion 264. Similarly, as shown in Figure 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] Referring to the example shown in Figures 16-18, the rocker assembly 310 includes, but is not limited to, a sill outer, a sill inner, and a rocker insert 340 positioned within the elongated interior of the sill structure, and includes features similar to those described above with respect to the rocker assembly 10 shown in Figures 1-9B. The rocker insert 340 similarly includes a first stiffening member 341 that, together with the rocker insert 340, defines a top wall 380, a bottom wall 382, ​​and a side wall 384 integrally connecting the top wall and the bottom wall. The rocker insert 340 also similarly includes a second stiffening member 342 that includes a wall portion 346 having a front edge 348 and a rear edge 350 positioned at different locations along the length of the rocker insert 340. However, as shown in the examples in Figures 10-12, the angled portion 368 of the second stiffening member 342 extends from the upper wall portion 362 at an angle of approximately 90 degrees before reaching the reinforcing rib 370, and then continues inward from the reinforcing rib 370, extending diagonally toward the upper wall portion 362. Thus, the distance between the first upper wall portion 362 and the second upper wall portion 362 is smaller than the width of the lower wall portion 364. Similarly, as shown in Figure 11, the distance between the first lower wall portion 364 and the second lower wall portion 364 is smaller than the width of the upper wall portion 362.

[0050] Referring to the example shown in Figures 19-22, the rocker assembly 410 includes, but is not limited to, a sill outer, a sill inner, and a rocker insert 440 positioned within the elongated interior of the sill structure, and includes features similar to those described above with respect to the rocker assembly 10 shown in Figures 1-9B. The rocker insert 440 similarly includes a first stiffening member 441 that, together with the rocker insert 440, defines a top wall 480, a bottom wall 482, and a side wall 484 integrally connecting the top wall and the bottom wall. The 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 positioned at different locations along the length of the rocker insert 440. Furthermore, the second stiffening member 424 is similar in shape to the shape described with respect to the example shown in Figures 1-9B. However, the second stiffening member 42 includes a second structure having the same shape that is positioned inside. In this example, the upper wall portion 462 of the second stiffening member 424 is connected to the top wall 80 of the first stiffening member 444. Furthermore, the lower wall portion 464 of the second stiffening member 424 is connected to the bottom wall 482 of the first stiffening member 441. As additionally shown in Figures 19-24, the reinforcing rib 470 may have a more angular shape than the more curved shape shown in the example in Figures 1-9B. Furthermore, the reinforcing rib 470 may, if desired, be positioned at an angled portion near the upper wall portion 462 or near the lower wall portion 464.

[0051] Referring to the example shown in Figures 22-24, the rocker assembly 510 includes, but is not limited to, a sill outer, a sill inner, and a rocker insert 540 positioned within the elongated interior of the sill structure, and includes features similar to those described above with respect to the rocker assembly 10 shown in Figures 1-9B. The rocker insert 540 similarly includes a first stiffening member 541 that, together with the rocker insert 540, defines a top wall 580, a bottom wall 582, and a side wall 584 integrally connecting the top wall and the bottom wall. The rocker insert 540 also similarly includes a second stiffening member 542 that includes a wall portion 546 having a leading edge 548 and a trailing edge 550 positioned at different locations along the length of the rocker insert 540. However, as shown in the example shown in Figures 22-24, the angled portion 568 of the second stiffening member 542 extends at a larger angle than shown in Figures 1-9B. The extending angle is greater than 90 degrees and may range from 95 to 130 degrees. Furthermore, upon reaching the reinforcing rib 570, the angled portion 568 extends backward at a similar angle toward the lower wall portion 564. Thus, the distance between the first upper wall portion 562 and the second upper wall portion 562 is approximately equal to the width of the lower wall portion 564. Similarly, as shown in Figure 23, the distance between the first lower wall portion 564 and the second lower wall portion 564 is approximately equal to the width of the upper wall portion 562.

[0052] Referring to the examples shown in Figures 25-27, the rocker assembly 610 includes, but is not limited to, a sill outer, a sill inner, and a rocker insert 640 positioned within the elongated interior of the sill structure, and includes features similar to those described above for the rocker assembly 10 shown in Figures 1-9B. The 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 the top wall and the bottom wall. The rocker insert 640 also similarly includes a second stiffening member 642 having a wall portion 646 with a front edge 648 and a rear edge 650 positioned at different locations along the length of the rocker insert 640. Furthermore, the examples shown in Figures 25-27 have an extended angle of the angled portion similar to the examples shown in Figures 22-24. However, as shown in the examples in Figures 25-27, 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. Thus, 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 Figure 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] Referring to the examples shown in Figures 28-30, the rocker insert 740 includes features similar to those described above with respect to the rocker assembly 10 and corresponding insert 40 shown in Figures 1-9B, and includes a first stiffening member 741 having a top wall 780, a bottom wall 782, and side walls 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 position spaced 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 walls 784 of the first stiffening member and are aligned axially with the in-cabin lateral impact force on the vehicle. In some examples, the second stiffening member 742 may be an aluminum extruded material, such as shown in Figure 28, thereby providing additional shapes from shapes formed from metal sheets. For example, as shown in Figure 28, the extruded second stiffener 742 includes an intermediate wall 792 extending between wall sections 768 that span between the top and bottom walls 780, 782 of the first stiffener. Thus, the intermediate wall 792 provided in the extruded second stiffener 742 can function to further reinforce the top and bottom walls 780, 782 against each other. Furthermore, in additional examples, the second stiffener when formed by extrusion may have various alternative cross-sectional shapes and features, such as honeycomb or lattice shapes. Moreover, the second stiffener when formed by extrusion may be a segmented piece along its length, such as a piece formed by cutting an elongated extruded product (where the wall sections are continuous along the length of the extruded product) into pieces and oriented them in parallel along the channel of the first stiffener. Thus, the second stiffening member 742 may include an extruded product in which a plurality of wall sections 768 are arranged in the extrusion direction, as shown in Figure 28.

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

[0055] Similarly, the rocker insert 840 shown in Figures 31-33 also includes a second stiffening member 842, which includes a wall section 846 comprising an upper wall portion 862 engaged with the top wall 880 and a lower wall portion 864 engaged with the bottom wall 882 at a position spaced apart from the upper wall portion 862 along the length of the rocker insert. The wall section 846 of the second stiffening member 842 extends perpendicular to the side wall 884 of the first stiffening member and is aligned axially with the in-cabin 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 a corrugated structure having peaks in the upper wall portion 862 and valleys in the lower wall portion 864, which are alternately arranged at spaced positions to repeat along the length of the rocker insert 840. However, unlike the examples shown in Figures 1-9B, the second stiffening member 842 is segmented along its length so as to be formed from a plurality of separate repeating sections along the length of the second stiffening member. These separate repeating sections are formed in the same shape so that they are formed into a single beam in a direction aligned with the wall direction and the direction of potential in-cab lateral impact, and can then be cut along the length of the beam to form individual sections or segments.

[0056] Referring to the example shown in Figures 34-36, the rocker assembly 910 includes, but is not limited to, a rocker insert 940 configured to be positioned within the elongated interior of the sill outer, sill inner, and sill structure, and includes features similar to those described above with respect to the rocker assembly 810 shown in Figures 31-33. The rocker insert 940, together with the rocker insert 840, similarly includes a first stiffening member 941 defining a top wall 980, a bottom wall 982, and a side wall 984 integrally connecting the top and bottom walls. The rocker insert 940 also similarly includes a second stiffening member 942, which includes an upper wall portion 962, a lower wall portion 964, and a wall section 946 including an angled portion extending between the upper and lower wall portions 962, 964 to define a corrugated structure. Furthermore, the second stiffening member 942 is also segmented along its length so as to be formed from a plurality of separate repeating sections. However, as shown in Figure 35, the recess 990 in the side wall 984 has a short projection toward the flange 988 and a short height on the side wall 984. The recess 990 forms a non-planar component along the length of the rocker insert 940, and the outer edge of the second stiffener member 942 is molded to fit the non-planar component. More specifically, the shape of the outer edge of the second stiffener member generally conforms to and fits the shape provided by the side wall 984.

[0057] Referring to the example shown in Figures 37-39, the rocker assembly 1010 includes, but is not limited to, a rocker insert 1040 configured to be positioned within the elongated interior of the sill outer, sill inner, and sill structure, and includes features similar to those described above with respect to the rocker assembly 810 shown in Figures 31-33. The rocker insert 1040 similarly includes a first stiffening member 1041 that, together with the rocker insert 1040, defines a top wall 1080, a bottom wall 1082, and a side wall 1084 integrally connecting the top wall and the bottom wall. The rocker insert 1040 also similarly includes a second stiffening member 1042 that includes a wall section 1046 defining a corrugated structure. Furthermore, the second stiffening member 1042 is also segmented along its length so as to be formed from a plurality of separate repeating sections. However, the side wall 1084 lacks recesses or concave structures, such as having a substantially planar shape as shown in Figure 38. The outer edge of the second stiffening member 1042 is molded to conform to the planar components, but the upper and lower outer 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 the bottom wall 1082.

[0058] Referring to the example shown in Figures 40-42, the rocker assembly 1110 includes, but is not limited to, a rocker insert 1140 configured to be positioned within the elongated interior of the sill outer, sill inner, and sill structure, and includes features similar to those described above with respect to the rocker assembly 1010 shown in Figures 37-39. The rocker insert 1140 similarly includes a first stiffening member 1141 that, together with the rocker insert 1140, defines a top wall 1180, a bottom wall 1182, and a side wall 1184 integrally connecting the top wall and the bottom wall. The rocker insert 1140 also similarly includes a second stiffening member 1142 that includes a wall section 1146 defining a corrugated structure. In addition, the second stiffening member 1142 is also segmented along its length so as to be formed from a plurality of separate repeating sections. Furthermore, the side wall 1184 lacks both recesses and concave structural portions, and the outer edge of the second stiffening member 1142 is shaped to conform to the planar structural portion. However, the upper and lower corners on the first stiffening member 1142 that separate the side wall 1184 from the top wall 1180 and the bottom wall 1182 have chamfered shapes corresponding to the chamfer angles at the upper and lower outer corners of the second stiffening member 1142.

[0059] The internal reinforcement of the disclosed vehicle rocker assembly may also be incorporated into other types of structural beams, such as frames and structures for automobiles and ships, buildings, storage tanks, furniture, etc. With regard to vehicle applications, the vehicle components disclosed herein can be incorporated into various applications of different structural components. Vehicle components can be designed to support and withstand different load conditions, such as supporting specific horizontal span or axial load conditions. Vehicle components can also be designed to withstand various impact forces, such as for the illustrated rocker assembly, pillar structure, and similar. The cross-sectional shape, material type selection, and material thickness within the cross-sectional profile of the vehicle component can be configured to suit such specific applications and desired load and performance characteristics, such as the weight of the vehicle component, beam load-bearing capacity, force deflection performance, and impact performance.

[0060] For the purposes of this disclosure, the term “joined” (in all its forms, joining, being joined, joined, etc.) generally means that two components are joined to one another, directly or indirectly. Such joining may be essentially stationary or essentially movable, and may be achieved by the two components and any additional intermediate members forming a single unit together, or by the two components themselves, and may be essentially permanent or essentially removable or detachable, unless otherwise specified.

[0061] The articles “a,” “an,” and “it” are intended to indicate that there is one or more of the elements in the preceding description. The terms “equip,” “include,” and “have” are intended to be inclusive and mean that there may be additional elements other than those listed. Furthermore, it should be understood that any reference in this disclosure to “one embodiment” or “embodiment” is not intended to be construed as excluding the existence of additional implementations that also incorporate the mentioned features. In addition, terms such as “first,” “second,” etc., when used herein, do not indicate order, quantity, or importance, but are used to represent elements from another element.

[0062] The numbers, percentages, ratios, or other values ​​described herein are intended to include those values ​​and other values ​​that are described as “about” or “approximately” as understood by those skilled in the art, and which are encompassed in the implementations of this disclosure. Accordingly, the described values ​​should be interpreted broadly enough to include values ​​that are at least sufficiently close to the described values ​​in order to perform the desired function or achieve the desired result. For example, the terms “approximately,” “about,” and “substantially” may refer to amounts that are less than 5%, less than 1%, less than 0.1%, and less than 0.01% of the described amount.

[0063] Furthermore, it should be understood that any direction or reference frame in the foregoing description is merely a relative direction or movement. For example, the terms “up,” “down,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” “inside the vehicle,” and “outside the vehicle,” and their derivatives, refer to the directions shown in Figure 1. However, it should be understood that various alternative orientations may be provided unless explicitly specified otherwise. It should also be understood that the particular apparatus and processes shown in the accompanying drawings and described herein are merely illustrative embodiments of the inventive concepts defined in the accompanying claims. Accordingly, specific dimensions and other physical characteristics relating to the embodiments disclosed herein should not be considered limiting unless explicitly stated in the claims.

[0064] Modifications and alterations in the embodiments specifically described may be carried out 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. This disclosure is written in an explanatory manner, and it will be understood that the terminology used is intended to be within the nature of the words described, and not limiting. Many modifications and alterations of this disclosure are possible in light of the above teachings, and this disclosure may be carried out in ways other than those specifically described.

Claims

1. A rocker assembly for a vehicle, A sill structure having an inner wall portion and an outer wall portion that define the elongated interior between them, 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, wherein the top wall, the bottom wall, and the side wall define a channel, and the side wall includes a recess projecting inward toward the vehicle-side wall portion of the sill structure, and A second stiffening member, at least partially disposed within the channel, wherein the second stiffening member includes a plurality of wall sections, each comprising an upper wall portion that engages with the top wall and a lower wall portion that engages with the bottom wall, wherein the lower wall portion engages with the bottom wall at a lower position spaced along the length of the rocker insert from the upper position where the upper wall portion engages with the top wall, The plurality of wall sections of the second stiffening member extend perpendicularly to the side wall of the first stiffening member and are aligned axially with the in-vehicle lateral impact force on the vehicle, rocker inserts including A locker assembly for a vehicle, including the locker assembly for the vehicle.

2. The rocker assembly according to claim 1, wherein the top wall includes a flange portion, and the flange portion extends at an angle to the rest of the top wall.

3. The rocker assembly according to claim 1, wherein the bottom wall includes a flange portion, and the flange portion extends at an angle to the rest of the bottom wall which is arranged parallel to the top wall.

4. The top wall includes a flange portion, and the flange portion of the top wall extends at a first angle with respect to the rest of the top wall. The rocker assembly according to claim 1, wherein the bottom wall includes a flange portion, and the flange portion of the bottom wall extends from the rest of the bottom wall at a second angle.

5. The rocker assembly according to 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 in-vehicle wall portion of the sill structure.

6. The rocker assembly according to claim 1, wherein the top wall and bottom wall of the first stiffening member are configured to be supported by the second stiffening member when subjected to the in-vehicle lateral impact force.

7. Each of the upper wall portions of the plurality of wall sections engages at a first position along the length of the rocker insert, The lower wall portion engages at a second position along the length of the rocker insert, The rocker assembly according to claim 1, wherein the distance between the first position and the second position is substantially the same for each of the plurality of wall sections along the rocker insert.

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

9. The second stiffening member includes a metal plate having a length that extends along the longitudinal range inside the hollow interior, The rocker assembly according to claim 1, wherein the plurality of wall sections define a corrugated structure having peaks and valleys alternately arranged at spaced intervals along the length of the metal plate.

10. A rocker insert configured to be positioned along the elongated hollow interior of a vehicle sill structure, A first stiffening member having a top wall, a bottom wall, and a side wall extending integrally between the top wall and the bottom wall, wherein the top wall, the bottom wall, and the side wall together define a channel, A second stiffening member, at least partially disposed within the channel, comprising a plurality of wall sections, each comprising an upper wall portion that engages with the top wall and a lower wall portion that engages with the bottom wall, wherein the lower wall portion engages with the bottom wall at a lower position spaced along the length of the rocker insert from the upper position where the upper wall portion engages with the top wall, The plurality of wall sections of the second stiffening member extend perpendicularly to the side wall of the first stiffening member and are aligned axially with the in-vehicle lateral impact force on the vehicle sill structure, and the plurality of wall sections include angled portions that extend between the upper wall portion and the lower wall portion and are configured to support the top wall and bottom wall of the first stiffening member when subjected to the in-vehicle lateral impact force. The side wall of the first stiffening member includes a non-planar portion along the length of the rocker insert, The outer edge of the second stiffening member is molded to fit the non-planar component. Rocker insert.

11. The top wall includes a flange portion, and the flange portion extends at an angle to the rest of the top wall. The rocker insert according to claim 10, wherein the flange portion is configured to connect with the inner wall of the vehicle sill structure.

12. The bottom wall includes a flange portion, and the flange portion is arranged parallel to the top wall. The rocker insert according to claim 10, which extends at an angle with respect to the remaining portion of the bottom wall.

13. The top wall includes an upper flange portion, and the upper flange portion extends at a first angle with respect to the rest of the top wall. The rocker insert according to claim 10, wherein the bottom wall includes a lower flange portion, and the lower flange portion extends at a second angle with respect to the rest of the bottom wall.

14. Each of the upper wall portions of the plurality of wall sections engages at a first position along the length of the rocker insert, The lower wall portion engages at a second position along the length of the rocker insert, The rocker insert according to claim 10, wherein the distance between the first position and the second position is substantially the same for each of the plurality of wall sections along the rocker insert.

15. The rocker insert according to claim 10, wherein the second stiffening member comprises a plurality of separate repeating sections along the length of the second stiffening member.

16. The second stiffening member includes a metal plate having a length that extends along the longitudinal range of the hollow interior, The rocker insert according to claim 10, wherein the plurality of wall sections define a corrugated structure having peaks and valleys alternately arranged at spaced intervals along the length of the metal plate.

17. A vehicle beam component, A first stiffening member having a first wall, a second wall positioned parallel to the first wall, and a third wall extending between the first wall and the second wall, wherein the first wall, the second wall and the third wall define a channel, and the third wall includes a recess projecting inward toward the channel, A second stiffening member, at least partially disposed within the channel, includes a plurality of wall sections, each comprising a first end portion that engages with the first wall, and a second end portion that engages with the second wall, wherein the second end portion engages with the second wall at a second position spaced along the length of the vehicle beam component from a first position where the first end portion engages with the first wall, The plurality of wall sections include angled portions that extend between the first end portion and the second end portion and are configured to support the first wall and the second wall of the first stiffening member when subjected to an inward 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 a lateral impact force on the inside of the vehicle. Vehicle beam components.

18. 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 in-vehicle lateral impact force, The vehicle beam component according to claim 17, wherein the second stiffening member includes a plurality of separate repeating sections along the length of the vehicle beam component.

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