BEAM ASSEMBLY WITH MULTIPLE OPENINGS

Abstract

A beam assembly includes a first beam having a first tubular portion and a first projection portion extending from the first tubular portion. A second beam has a second tubular portion and a second projection portion extending from the second tubular portion. The elongated interior of the first tubular portion defines a first hollow area, and the elongated interior of the second tubular portion defines a second hollow area. The first beam is joined to the second beam, with the first projection portion joined to the second tubular portion and the second projection portion joined to the first tubular portion to define a third hollow area between the first and second projection portions.

Description

BEAM ASSEMBLY WITH MULTIPLE OPENINGS Field of Invention The present description generally refers to a beam component, and more specifically to a tubular beam with at least one hollow interior, such as for use as a vehicle bumper reinforcement, a structural frame component, a battery tray component, or the like. Background of the Invention Vehicle beams used for structural reinforcement and support are typically designed for a specific vehicle application and mounting location. The cross-sectional shape of a beam used as a vehicle structural component is commonly designed to have a geometric form that corresponds to a desired packing space, bending strength, and impact energy management characteristics for the application and location within the vehicle architecture. Furthermore, a roll-formed beam designed for a specific component uses a custom set of rolling tooling, so alterations to the cross-sectional shape or design of a roll-formed beam often require the costly investment of additional custom rolling tooling. frczn Ln / zznz / E / YiAi Ref. 337385 Summary of the Invention This description provides a life-size assembly that incorporates multiple elongated beams into a single elongated beam assembly. The beam assembly may include beam sections cut from an individual elongated beam and joined together in parallel alignment to provide a stronger elongated beam structure with a desired cross-sectional shape, such as a cross-section with multiple hollow areas and / or multiple shear walls. In this way, at least some of the beam sections joined together to form the beam assembly may have the same cross-sectional shape. By doing so, desired cross-sectional attributes of the beam assembly can be achieved with reduced tooling that might otherwise be required to form a single beam with cross-sectional attributes similar to the beam assembly. According to one aspect of this description, a beam assembly includes a first beam having a first tubular portion and a first projection portion extending from a first joint along the first tubular portion. A second beam has a second tubular portion and a second projection portion extending from a second joint along the second tubular portion. The elongated interior of the first tubular portion defines a first hollow area, and the elongated interior of the second tubular portion defines a second hollow area. The first beam is joined to the second beam, with the first projection portion attached to the second tubular portion and the second projection portion attached to the first tubular portion to define a third hollow area between the first and second projection portions. In some implementations, the first and second beams have the same cross-sectional shape, such as a P-shaped cross-section extending continuously along the length of the respective beam. Also, in some examples with the first beam positioned vertically above the second beam, the bottom wall of the first beam and the top wall of the second beam may be substantially flat and parallel to define internal shear walls of the beam assembly. In further implementations, each beam can be formed by rolling a metal sheet made of high-strength steel, ultra-high-strength steel, or aluminum, among other metals. The first and second beams can be joined together by welding, such as with continuous welding along their length. In other respects, the beam assembly may include a third beam having a third tubular portion and a third projection portion extending from a third joint along the third tubular portion. The third beam may have the same cross-sectional shape as the first and second beams. In some examples, the third beam may be attached to the second beam with the third projection portion arranged perpendicular to the first and second projection portions, such as to form a floor surface for a vehicle battery tray. Optionally, the beam assembly can be installed as a vehicle frame component, such as a rocker beam, rocker insert, floor cross member, roof cross member, pillar structure, or other structural vehicle component. In some implementations, the beam assembly can be used as a bumper reinforcement beam, door beam, or as part of another impact energy management structure. Additionally, in some examples, the beam assembly can be used as a battery tray component, such as a tray frame wall or cross member. In accordance with another aspect of the present description, the beam assembly includes a first beam having a first tubular portion and a first projection portion extending along the first tubular portion. The beam assembly also comprises a second beam including a second tubular portion and a second projection portion extending along the second tubular portion. The first and second beams are formed from a metal sheet, such that each of the first and second tubular portions has a joint arranged along a length thereof defined by an edge section of the metal sheet joined along an intermediate section of the metal sheet. The first and second projection portions project integrally at the joint from the intermediate section of the metal sheet.The first beam is joined to the second beam with the first projection portion joined to the second tubular portion and the second projection portion joined to the first tubular portion to define a hollow area between the first and second projection portions. These and other objectives, advantages, purposes, and characteristics of the present description will become evident after reviewing the following description in conjunction with the figures. Brief Description of the Figures Figure 1 is a top perspective view of a vehicle that schematically illustrates several examples of beam mountings; Figure 2 is a side elevation view of the frC7n ίη / 77Π7 / E / YΙΛΙ vehicle shown in Figure 1 which schematically illustrates additional examples of beam assemblies; Figure 3 is a top perspective view of an illustrative beam assembly; Figure 3A is a cross-sectional perspective view of the beam assembly shown in Figure 3, taken in line AA; Figure 4 is an end view of the beam assembly shown in Figure 3; Figures 5-10 are end views of additional examples of a beam assembly; Figure 11 is a side elevation view of a vehicle schematically illustrating a further example of a beam mounting of a battery tray structure; and Figure 12 is a cross-sectional view of a side wall portion of the battery tray structure shown in Figure 11. Detailed Description of the Invention With reference to the figures and illustrative embodiments shown therein, a beam assembly is provided that can be used in various beam applications, such as automotive vehicle components or structures, including electric vehicles (EVs) and internal combustion engine vehicles (ICEs), such as vehicle 100 shown in Figures 1 and 2. The beam assembly, such as those shown in Figures 3-12, incorporates multiple elongated beams into a single elongated beam assembly. As shown in Figures 3-4, the beam assembly 10 includes a first beam 12 having a tubular portion 14 with an elongated hollow interior 16 and a projecting portion 18 extending outward from a joint extending along the tubular portion 14.A second beam 22 also has a tubular portion 24 with an elongated hollow interior 26 and a projecting portion 28 extending outward from a joint that runs along the length of the tubular portion 24. In this way, the first and second beams 12, 22 can each have the same cross-sectional shape, such as a P-shaped cross-section. Generally with the same cross-sectional shape, the first and second beams 12, 22 can, prior to assembly, be cut from a single elongated beam, such as a beam formed by continuous rolling. The first and second beams 12, 22 are joined together in parallel alignment and along each other to combine into a desired cross-sectional shape for the overall beam assembly 10. To form the beam assembly 10, the first and second beams 12, 22 can be arranged in a mirrored relationship, flipped through a longitudinal plane that extends axially between the tubular portions 14, 24 of the first and second beams 12, 22. In other words, when starting with the first and second beams 12, 22 in the same orientation, one of the beams is axially rotated about its longitudinal axis approximately 180 degrees relative to the other beam before joining the beams 12, 22 together.As shown for example in Figures 3-4, the first beam 12 is joined to the second beam 22 with the projection portion 18 of the first beam 12 joined to the tubular portion 24 of the second beam 22 and the projection portion 28 of the second beam 22 joined to the tubular portion 14 of the first beam 12 to define at least two separate joining points 30 or joints arranged between the beams 12, 22 longitudinally along the length of the beam assembly 10. The joining points 30 may be formed by welding, such as continuous welded joints or intermittent spot welds, or they may be formed by other types of joining, such as adhesive or fasteners or the like. As shown in Figures 3-4, the opposite walls 34 of the tubular portions 14, 24 of the first and second beams 12, 22, which face each other, can be spaced far apart to define an elongated hollow area 32 between the beams 12, 22. The hollow area 32 is also bounded between the projection portions frC7n ίη / 77Π7 / E / YΙΛΙ 18, 28 of beams 12, 22. With the spacing provided by the defined central hollow area 32 of beam assembly 10, the opposing walls 34 of the tubular portions 14, 24 can function to reinforce the overall interior area of ​​beam assembly 10, such as by acting as internal shear walls of beam assembly 10. In addition, the opposing walls 34 of beam assembly 10 divide the interior area to provide a multi-hollow shape defined by the hollow interiors 16, 26 of the tubular portions 14, 24 of the respective beams 12, 22 and the central or third hollow area 32 disposed between the tubular portions 14, 24. It is envisaged that additional examples of the beam assembly may have various cross-sectional shapes and alternative configurations, such as with additional or alternative beams, joining points, or hollow areas to provide the desired cross-sectional shape of the beam assembly. The cross-sectional shape of the perimeter of the beam assembly 10 can be rectangular, as also shown in Figures 3-4. In addition, the tubular portions 14, 24 can each have a generally rectangular cross-sectional shape defined by four orthogonally arranged wall sections. For example, as shown in Figure 4, the beams 12, 22 can be formed by rolling from a metal sheet to form the tubular portions 14, 24 with a first wall section 34, a second wall section 36, a third wall section 38, and a fourth wall section 40, which together comprise a rectangular cross-section. The tubular portions 14, 24 have three rounded corners 42 that are defined by the bent radius of the sheet metal, which may be limited by the material thickness and material ductility, such as greater than approximately four times the thickness of the sheet metal.Each of the beams can be formed by rolling with a metal sheet that is made of high-strength steel, ultra-high-strength steel, or aluminum, among other metals. As shown in Figure 4, the remaining square corner 44 of the tubular portion 14, 24 is formed by an edge 46 of the first wall section 34, which is joined at an intermediate location on the sheet metal between the fourth wall section 40 and the projection portion 18, 28. The joint formed at the edge 34 of the sheet metal can be joined by welding the edge 46 against the sheet metal, such as by forming a fillet weld or similar. Such welding can be done, for example, by intermittent spot welding or continuous welding along the length of the beam. The joining location of the first wall section 34 in the sheet forms a joint and generally separates the fourth wall section frczn Ln / zznz / E / YiAi and the projection portion 18, 28. As shown in Figure 4, the projection portions 18, 28 extend from the tubular portions 14, 24 in planar alignment with the respective fourth wall section 40.When the two separate beams 12, 22 are joined, the third hollow area 32 formed between the beams is surrounded by the projection portions 18, 28 and the fourth wall sections 40 of the tubular portions 14, 24. With further reference to Figures 3-4, each of the tubular portions 14, 24 may include a recessed area 38 to receive the edge of the projection portion 18, 28 of the other beam. The recessed area 38, shown in Figure 4, is disposed in the second wall section 36 and has a depth that projects inward into the respective hollow interior area 16, 26 at a distance generally equal to the thickness of the mating edge of the projection portion 18, 28. The approximate depth of each recessed area 48 shown in Figure 4 is measured between the flat outer surface of the second wall section 36 and the flat outer surface in the recessed area 48, which is generally equal to the thickness of the sheet metal of the other beam.The recessed area 48 generally aligns the flat outer surface of the second wall section 36 with the outer surface of the attached projection portion 18, 28, which can also align with the outer surface of the fourth wall section 40 from which the respective projection portion 18, 28 extends. The aligned projection portions 18, 28, second wall sections 36, and fourth wall sections 40 together form parallel and opposite outer walls of the overall beam assembly 10. Referring now to Figures 5-10, additional examples of a beam assembly 110 (Figure 5), 210 (Figure 6), 310 (Figure 7), 410 (Figure 8), 510 (Figure 9), 610 (Figure 10) are shown to illustrate alternative cross-sectional shapes to those illustrated in Figures 3-4. For example, in the orientation shown in Figure 5, the beam assembly 110 has a reduced horizontal width compared to the beam assembly 10 shown in Figure 4. The reduced width of the beam assembly 110 is provided by the reduced-width tubular portions 114, 124 of each beam 112, 122, and more specifically, the shorter length of the first and third wall sections 134, 138. The beam assembly 110 shown in Figure 5 can generally be formed with the same length of the second and fourth wall sections 136, 140, the same length of the projection portion 118, 128, and the same number of bends as the beam assembly 10 shown in Figure 4.However, the radius of curvature at the corner bends 142 is larger at frC7n ίη / 77Π7 / Ε / ΥΙΛΙ. Figure 5 shows that the corner bends 42 in Figure 4 and the overall width of the sheet metal used to form each beam 112, 122, the beam assembly 110 in Figure 5 is less than the width of the sheet metal used to form beams 12, 22 in Figure 4. Furthermore, as shown in the orientation in Figure 6, the beam assembly 210 has the same rectangular perimeter cross-section as the beam assembly 10 shown in Figure 4, but it has internal shear walls located closer together. The closer shear walls are provided by the tubular portions 214, 224 of each beam 212, 222 that have an increased height, and more specifically, the second and fourth wall sections 236, 240 that have a greater length. To maintain the same overall height of the beam assemblies 10, 210 in Figures 4 and 6, the projecting portions 218, 228 of the beam assembly 210 in Figure 6 are reduced in length by the same overall length that the tubular sections increase in height.Thus, the dimensional alterations shown in Figure 6 can be formed with the same sheet metal, bend configurations, and rolling tool, but by altering the positions of the rolling tool on the rolling line. Therefore, the beam assembly in different examples can include several dimensional variations. The beam assembly may also include one or more channel ribs to reinforce a portion of the beam assembly. As shown, for example, in Figure 7, the projection portions 318, 328 of the beam assembly 310 each include a channel rib 320 in a central section thereof and extending along a length of the respective beam 312, 322. When locating the channel ribs 320 in the projection portions 318, 328, the channel ribs 320 are arranged in a central vertical location of the beam assembly 310 and project out on opposite sides of the central or third hollow area 332. The beam assembly 310 shown in Figure 7 is otherwise similar to the beam assembly 10 shown in Figure 4, such that channel rib alterations can be made by increasing the width of the sheet metal and by adding a rolling tool that forms a channel rib 320 in the projection portion.In additional examples, it is contemplated that additional channel ribs may be provided in other portions of a beam assembly, such as in wall sections of tubular portions. As further shown in Figure 8, the beam assembly 410 has the same general cross-sectional shape as the beam assembly 10 shown in Figure 4, except for the connection of the edge portion 446 of the first wall section 434 to the sheet metal. As shown in Figure 8, the connection shape of the edge portion 446 of the sheet metal may include a corner bend 442, such that a flat side surface of the sheet metal at the edge portion 446 is joined to the flat side surface of the sheet metal between the fourth wall section 440 and the projection portion 418, 420. This flat surface connection may be provided by welding, for example, by intermittent spot welding or continuous welding along the length of the beam.For example, a laser weld can be formed by orienting the laser head generally perpendicular to the outer surface of the sheet metal, so that the laser weld can be formed perpendicularly through the portion of the sheet metal that overlaps with the edge portion 446. As shown in Figure 8, the edge portions 446 are bent to extend into the hollow interior areas 416, 426 of the respective beams 412, 422. As shown in Figure 8, the projection portions 418, 428 extend from the tubular portions 414, 424 in planar alignment with the edge portions 446 and the respective fourth wall section 440. Similarly, as shown in Figure 10, the beam assembly 610 has the same general cross-sectional shape and edge portion joining as the beam assembly 410 shown in Figure 8, except for the joining of the projection portions 618, 628 to the tubular portions 614, 624 of the other respective beam. As shown in Figure 10, the edges of the projection portions 618, 628 may also include a corner bend 642, so that a flat side surface of the sheet metal in the projection portion 618, 628 joins to the flat side surface of the first wall section 634. This flat surface joining may be provided by welding, for example, by intermittent spot welding or continuous welding along the length of the beam.For example, a laser weld can be formed along the groove joint by orienting the laser head generally perpendicular to the outer surface of the second wall section 636 and the projection portions 618, 628. Also, as shown in Figure 10, the edges of the projection portions 618, 628 are bent to extend into the central inner areas 632. By doing so, the recessed area can be omitted from the second wall section. Furthermore, as shown in Figure 9, the projection portions 518, 528 join at the tubular portions 514, 524 and extend beyond the tubular portion to provide a flange 550, 552 for joining to an adjacent vehicle component. For example, the flanges frczn Ln / zznz / E / YiAi 550, 552 can be used to join the beam assembly 510 between inner and outer tilting bottom panels or can be used in place of either or both tilting bottom panel components. The flanges can be alternatively formed and located in different examples to provide a design that incorporates the corresponding vehicle design. As shown in Figure 9, the projection portions 518, 528 are arranged over the second wall sections 536 and each has a bend that corresponds to the corner bend 542 between the second wall section 536 and the third wall section 538, such that the projection portions 518, 528 follow along and over the third wall sections 538. As further shown in Figure 9, the projection portions have an outward-directing bend that directs the flanges 550, 552 orthogonally outward from the third wall section 538. Referring now to Figures 11 and 12, the beam assembly 710 includes a third beam 752 having a tubular portion 754 with an elongated hollow interior 756 and a projecting portion 758 extending from the tubular portion 754. As shown in Figure 12, the third beam 752 has the same cross-sectional shape as the first and second beams 712, 722, shown as a P-shaped cross-section. As such, the three beams 712, frczn Ln / zznz / E / YiAi Beams 722 and 752 can be cut from a single elongated beam, such as a beam formed by continuous rolling. Beams 712, 722, and 752 are joined in parallel alignment and lengthwise to combine to form a desired cross-sectional shape of beam assembly 710, which has four hollow interior areas. As further shown in Figures 11 and 12, the third beam 752 is joined to the second beam 722 with the projection portion 758 of the third beam 752 arranged perpendicular to the other projection portions 718 and 728 and is joined to a lower wall section 738 of the lower tubular portion. The first wall section 734 of the tubular portion 754 of the third beam 752 is also joined to the lower tubular portion at the second wall section 736. With this cross-sectional shape, the beam assembly 710 shown in Figure 12 can be used as a side wall 760 of a battery tray 762, as shown in Figure 11. The tubular portion 754 of the third beam 752 can be arranged on an outer side of the side wall 760 to assist with lateral impact energy absorption.Also, the projection portion 758 of the third beam 752 can be arranged on an inside side of the side wall 760 to form a floor support for a floor 764 of the battery tray 762, as well as any additional inside components of the battery tray 762. frczn Ln / zznz / E / YiAi With regard to various vehicle applications, the beam assembly can be used, for example, as a vehicle bumper reinforcement, a structural frame component, or a battery tray component. As shown, for example, in Figures 1 and 2, these include, for example, roof arches 102, headers 103, pillars 104, rocker arms 105, floor cross members 106, bumper beams 107, door beams 108, frame rail ends 109, and the like. As shown in Figures 1 and 2, the beam assembly can be designed to withstand various impact forces, such as for vehicle bumper reinforcement beams 107 and door beams 108 and the like. As further provided in the illustrative vehicle 100 shown in Figures 1 and 2, a body structure or frame 101 of the vehicle 100 has multiple structural beam components, one or all of which may be provided as a beam assembly as described herein.For example, the beam assembly can be designed to support and bear different load conditions, such as supporting horizontal spans, like a roof arch 102 and a tilting rail 105 or its insert, or supporting axial loads, like the vehicle frame pillars 104. Furthermore, as shown in vehicle 700 in Figure 11, the beam assembly can be used as a structural component of a battery tray 762, such as a perimeter side wall 760 or a crossbeam spanning between opposite side walls of the battery tray. The cross-sectional shape of the beam assembly can include various shapes and thicknesses for the desired application of the beam assembly, such as an open profile or a closed profile, which may include a multiple tubular profile having two or more hollow interior areas that extend longitudinally within the pultruded profile. For the purposes of this description, the terms top, bottom, right, left, rear, front, vertical, horizontal, and their derivatives refer to the apparatus as oriented in Figure 1. However, it should be understood that the apparatus can assume various alternative orientations, unless expressly stated otherwise. It is also understood that the specific devices and processes illustrated in the accompanying figures and described herein are merely illustrative modes or implementations. Accordingly, the terminology used is intended to be descriptive rather than limiting. Therefore, specific dimensions and other physical characteristics relating to the modes or implementations described herein are not to be considered limiting unless the claims expressly state otherwise.Many modifications and variations of the modalities and implementations are possible in view of the previous teachings. It is hereby stated that, as of this date, the best method known to the applicant for putting the aforementioned invention into practice is the one that is clear from the present description of the invention.

Claims

1. A beam assembly, characterized in that it comprises: a first beam having a first tubular portion and a first projection portion extending along the first tubular portion, wherein the first tubular portion surrounds a first hollow area; a second beam having a second tubular portion and a second projection portion extending along the second tubular portion, wherein the second tubular portion surrounds a second hollow area; and wherein the first beam is joined to the second beam with the first projection portion joined to the second tubular portion and the second projection portion joined to the first tubular portion to define a third hollow area between the first and second projection portions.

2. The beam assembly according to claim 1, characterized in that the first beam and the second beam each comprise the same cross-sectional shape.

3. The beam assembly in accordance with claim 2 of frC7n ίη / 77Π7 / E / YΙΛΙ 23, characterized in that the same cross-sectional shape is P-shaped.

4. The beam assembly according to claim 3, characterized in that the same cross-sectional shape extends continuously along a length of each of the first and second beams.

5. The beam assembly according to claim 4, characterized in that the first and second beams are joined by welding.

6. The beam assembly in accordance with any of the preceding claims, characterized in that the first tubular portion comprises a rectangular cross-section defined by four wall sections, and wherein the first projection portion extends from the first tubular portion in planar alignment with one of the four wall sections.

7. The beam assembly according to claim 6, characterized in that the third hollow area is surrounded by the first and second projection portions and by parallel wall sections of the first and second tubular portions.

8. The beam assembly according to claim 1, characterized in that each of the first and second projection portions includes a channel rib extending along a length of the respective first and second beams, and wherein the channel ribs are arranged on opposite sides of the third hollow area.

9. The beam assembly according to claim 1, characterized in that it further comprises: a third beam having a third tubular portion and a third projection portion extending along the third tubular portion, wherein each of the first, second and third beams comprises the same cross-sectional shape, and wherein the third beam is joined to the second beam with the third projection portion perpendicular to the first and second projection portions to form a floor support for a vehicle battery tray.

10. The beam assembly according to claim 1, characterized in that a wall of the first tubular portion comprises a flat section and a recessed section that is configured to couple with the second projection portion, and wherein the flat wall section of the first tubular portion is arranged in alignment with the second projection portion and together they form an outer wall of the beam assembly.

11. The beam assembly according to claim 1, characterized in that the first and second projection portions extend outwards from the frczn Ln / zznz / E / YiAi joint in the respective first or second tubular portion to define a flange, and wherein the flange assembly comprises at least one tilting section component.

12. A beam assembly, characterized in that it comprises: a first beam comprising a first tubular portion and a first projection portion extending along the first tubular portion; a second beam comprising a second tubular portion and a second projection portion extending along the second tubular portion; wherein the first and second beams are formed from a metal sheet, each of the first and second tubular portions having a joint arranged along a length thereof defined by an edge section of the metal sheet joined along an intermediate section of the metal sheet, and the first and second projection portions projecting integrally at the joint of the intermediate section of the metal sheet;And where the first beam is joined to the second beam with the first projection portion joined to the second tubular portion and the second projection portion joined to the first tubular portion to define a hollow area between the first and second projection portions. frczn Ln / zznz / E / YiAi; 13. The beam assembly according to claim 12, characterized in that a cross-sectional shape of the first beam taken transverse to the length thereof is like a cross-sectional shape of the second beam taken transverse to the length.

14. The beam assembly according to claim 13, characterized in that the cross-sectional shape of the first and second beams is P-shaped.

15. The beam assembly according to claim 12, characterized in that the first and second beams are joined by welding.

16. The beam assembly according to claim 12, characterized in that the first tubular portion comprises a rectangular cross-section defined by 4 wall sections, and wherein the first projection portion extends from the first tubular portion in planar alignment with one of the four wall sections.

17. The beam assembly according to claim 12, characterized in that each of the first and second beams includes a channel rib arranged along their length.

18. The beam assembly according to claim 12, characterized in that the first and second projection portions extend outwards from the joint of the respective first or second tubular portion to define a flange.

19. The beam assembly according to claim 12, characterized in that a wall section of the first tubular portion comprises a recessed area that couples to the second projection portion.

20. The beam assembly according to any of claims 12-19, characterized in that it comprises one of a roof arch, a header, a pillar, a rocker, a cross member, a bumper beam, a door beam, a frame rail tip, or a battery tray wall.

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