VEHICLE REINFORCEMENT BEAM

A reinforcement beam for a vehicle has an outer beam and an inner beam. The outer beam spans laterally between crush cans of the vehicle. The outer beam forms an elongated hollow body that has a front wall and a rear wall extending along the length of the reinforcement beam. The inner beam is disposed along an intermediate section of the outer beam. The inner beam further includes an upper wall and a lower wall that each extend between the front wall and the rear wall of the outer beam. The front wall and the rear wall may include at least one rib that extends along the length of the outer beam.

TECHNICAL FIELD

The present disclosure relates generally to reinforcement beams for vehicles, such as bumper reinforcement beams for bumper assemblies, subassemblies, and components thereof.

BACKGROUND

Vehicle bumper systems commonly include at least one reinforcement beam that spans across the front or rear end of the vehicle. The primary reinforcement beam is typically supported by crush cans that attach to the vehicle frame structure. Vehicle bumper systems undergo rigorous testing for impact energy management and absorption from high speed and low speed crash impacts, such as to comply with mandated government regulations and insurance certifications. For example, impact requirements and protocols for bumper systems are set forth by the United States Federal Motor Vehicle Safety Standards (US FMVSS), the Insurance Institute for Highway Safety (IIHS), the National Highway Traffic Safety Administration (NHTSA), the European EC E42 consumer legislation, and the Asian Pedestrian Protection for lower and upper legs, among others. Bumper systems are also designed to maximize strength-to-weight ratios in an effort to minimize the overall vehicle weight, while balancing the cost of the associate bumper system components.

SUMMARY

This disclosure provides a reinforcement beam for a vehicle that functions to receive and absorb impact loads delivered by vehicle collisions, such as implementations of a bumper reinforcement beam that is supported by crush cans at a vehicle frame. The bumper reinforcement beam includes an outer beam component configured to span laterally between the crush cans and an inner beam component that reinforces a central or intermediate section of the outer beam component, such that the inner beam component is omitted at the end sections of the outer beam that are otherwise supported to a greater extent by the crush cans. The outer beam component has an elongated hollow body formed from a metal sheet material, such as a front sheet and a rear sheet that are attached together along respective upper and lower flanges. The inner beam reinforces a hollow area between the front wall and the rear wall of the outer beam by providing an upper wall and a lower wall that extend between the front and rear walls. The inner beam may have a greater bending strength than the outer beam, such as a result of forming the inner beam with a metal sheet having a greater thickness or tensile strength or the like.

One aspect of the disclosure provides a bumper reinforcement beam that is configured to be supported by crush cans at a vehicle frame. The bumper reinforcement beam includes an outer beam and an inner beam. The outer beam has an elongated hollow body formed from a metal sheet material and configured to span laterally between the crush cans. The hollow body includes a front wall and a rear wall extending along a length defined between a first end and a second end of the hollow body. The inner beam is disposed along an intermediate section of the outer beam, where the inner beam has an upper wall and a lower wall that each extend between the front wall and the rear wall of the outer beam.

The front wall and the rear wall of the outer beam may include at least one rib that extends along the length of the outer beam. The inner beam may have a length between its opposing ends that is less than a half of the length of the outer beam. The end sections of the outer beam that are disposed at opposing ends of the central section may be void of the inner beam. In some aspects, the inner beam may be formed from a metal sheet material that has a greater thickness than the metal sheet material of the outer beam, such as twice the thickness or more or less than the metal sheet material of the outer beam.

The inner beam may have an intermediate portion or connecting wall that interconnects between the upper wall and the lower wall to define a channel along the inner beam. The intermediate portion may have a groove that is formed along a forward surface of the inner beam. The intermediate portion of the inner beam may be coupled to the front wall of the outer beam.

The upper and lower walls of the inner beam may divide the interior volume of the hollow body to form a plurality of elongated hollow areas. In some examples, the inner beam has rear flanges that integrally extend from the upper and lower walls. The rear flanges may attach to the rear wall of the outer beam. The upper and lower walls of inner beam may extend rearward at an angle of less than 40 degrees relative to normal to a planar extent of the front wall. In certain aspects, the upper wall of inner beam extends rearward and upward at an angle of less than 20 degrees relative to normal to a planar extent of the front wall. In some aspects, the lower wall of inner beam extends rearward and downward at an angle of less than 20 degrees relative to normal to a planar extent of the front wall.

The front wall of the outer beam may have one or more ribs that extend along the length of the outer beam. In some examples, the outer beam includes a front piece that has the front wall and a rear piece that has the rear wall. The front and rear piece may attached together along respective upper and lower flanges to enclose a hollow interior of the outer beam. In some examples, the upper and lower flanges are each attached together via welding. The upper flanges of the front and rear pieces may protrude upward from a hollow interior of the hollow body. The lower flanges of the front and rear pieces may protrude downward from the hollow interior of the hollow body.

The front and rear pieces of the outer beam may each be formed from a separate metal sheet. In some aspects, the rear piece of the outer beam comprises an upper wall and a lower wall that together with the rear wall define a C-shaped cross section. A rear surface of the rear piece may include an attachment surface that is adapted for attachment to the crush cans.

Another aspect of the disclosure provides a bumper reinforcement beam that is configured to be supported by crush cans at a vehicle frame. The bumper reinforcement beam includes a front beam piece having a front wall and a rear beam piece having a rear wall. The upper and lower edges of the rear beam piece that are attached along respective upper and lower edges of the front beam piece to define an elongated hollow body having a length configured to span between crush cans. An inner beam piece is attached between the front and rear beam pieces and includes an upper wall and a lower wall that extends between the front wall and the rear wall. The inner beam piece has a length that is less than half the length of the elongated hollow body.

Yet another aspect of the disclosure provides a reinforcement beam for a vehicle, where the reinforcement beam has an outboard beam component and an inboard beam component. The outboard beam component includes an outboard wall and the inboard beam component includes an inboard wall. The inboard beam component also includes upper and lower flanges that are attached along respective upper and lower edges of the outboard beam component to define an elongated hollow body with a length defined between opposing ends of the outboard beam component. The inner beam component is attached between the outboard and inboard beam components and includes a C-shaped cross section defining an upper shear wall and a lower shear wall that each extend between the outboard wall and inboard wall. The inner beam component has a length that is less than half the length of the elongated hollow body.

Each of the above independent aspects of the present disclosure, and those aspects described in the detailed description below, may include any of the features, options, and possibilities set out in the present disclosure and figures, including those under the other independent aspects, and may also include any combination of any of the features, options, and possibilities set out in the present disclosure and figures.

The details of one or more implementations of the disclosure are set forth in the accompanying drawings and the description below. Other aspects, advantages, purposes, and features will be apparent upon review of the following specification in conjunction with the drawings.

Like reference numerals indicate like parts throughout the drawings.

DETAILED DESCRIPTION

Reinforcement beams for vehicles are disclosed herein in various implementations as impact energy absorption and management devices that are used in conjunction with other vehicle components to absorb and manage impact loads and energy, while minimizing damage and intrusion during an impact to the vehicle. For example, a reinforcement beam may be employed at a bumper assembly that is attached to a vehicle frame, where the reinforcement beam is a cross car structure supported by crush cans. In some instances, vehicle bumper assemblies can have increased front end stiffness and impact energy absorption requirements, such as on electric vehicles or rear engine mounted vehicles with greater vehicle mass and front ends that may be more susceptible to impact intrusion. While it is generally known that bumper reinforcement beams with increased mass can function to meet increased stiffness requirements, increasing mass typically adds to the vehicle cost while also reducing range and/or fuel efficiency.

The reinforcement beam12of the disclosure includes an outer beam component20and an inner beam component22that reinforces an intermediate section24(FIG.3) of the outer beam component20. The outer beam component20has an elongated hollow body, which may be formed from a metal sheet material. For example, as shown inFIG.4A, the outer beam component20, includes a front piece26and a rear piece28that may be attached together along their respective upper and lower edges27,29, such as along defined upper and lower flanges. The inner beam component22reinforces a hollow area between the front wall30and the rear wall32of the outer beam component20by providing an upper wall34and a lower wall36that each extend between the front and rear walls30,32.

As described here, reference to front and rear and other directional derivatives for this example of the reinforcement beam is in reference to its use on a front bumper assembly (FIG.1) and its relative location on the associated vehicle100. However, it is understood that the reinforcement beam disclosed herein may also be used on a rear bumper assembly13or a side frame structure15(FIG.1A), such as a rocker or a battery tray side member, among other conceivable uses on a vehicle structure or subassembly to absorb and manage impact loads and energy.

Referring now to the drawings and the illustrative examples depicted therein, a bumper assembly10for a vehicle100, such as shown inFIG.1, has a bumper reinforcement beam12that is supported by crush cans14that are attached to the bumper reinforcement beam12at generally equal spacing from a center of the bumper reinforcement beam12. The crush cans14of the bumper assembly10each mount to an end or tip of a frame rail16or other supportive portion of a vehicle frame to position the bumper reinforcement beam12so that it spans laterally (in a width direction of the vehicle) across a front end of the vehicle100. As shown inFIG.1, the bumper assembly10is mounted at the front end of the vehicle100, which may be a passenger vehicle or other type of motor vehicle, such as a car, truck, bus, van, or sport utility vehicle or the like. The crush can14functions to support the bumper reinforcement beam12at the vehicle frame16and to direct and absorb impact loads18received (in a longitudinal or x-direction relative to the vehicle) from the supported bumper reinforcement beam12to the attached frame16through the crush can14. It is also contemplated that the bumper assembly and other implementations thereof may be used or otherwise incorporated into a rear end or other areas of a vehicle. As shown inFIG.1A, various reinforcement beams for a vehicle100are depicted therein in dashed lines. Implementations of the bumper assembly may be incorporated into other vehicle structural members such as those illustrated, including a rear bumper, roof rails, A-pillars, and B-pillars.

As shown for example inFIG.2, a bumper reinforcement beam12and crush can14are illustrated. The crush can14is formed as a thin-walled, hollow structure that is a frangible structure designed to crush to absorb impact energy received at the bumper reinforcement beam12. The bumper assembly10may include one or more attachment plates17between the crush can14and the bumper reinforcement beam12or between the crush can14and the vehicle frame component16(FIG.1), or both. The one or more attachment plates17may include a distribution of apertures for attachment to the bumper reinforcement beam12or the vehicle frame component16with threaded or similar fasteners, such as bolts, rivets, or the like. The crush can14may be welded to the one or more attachment plates17. Alternatively, the crush can14may be welded directly to the bumper reinforcement beam12, or to the vehicle frame component16, or both.

As further shown inFIGS.2and3, the inner beam component22of the bumper reinforcement beam12reinforces an intermediate section24of the outer beam component20. The intermediate section24may include a central section of the outer beam component20as shown inFIG.3. In other examples, the intermediate section24may be off-center along the length of the outer beam component20. As illustrated inFIG.3, the intermediate section24may include one position along the length of the outer beam component20, such that the bumper assembly10includes one inner beam component22. In other examples, more than one intermediate section24and more than one inner beam component22may be included along the length of the outer beam component20. By adding more than one inner beam component22, the beam assembly10may drive buckle points to specific locations without the added support of the inner beam component22. The inner beam component22has a length between its opposing ends that is less than a half of the length of the outer beam component22. For example, the length of the outer beam component may be in a range approximately between 800 mm and 1,600 mm, or in a range between 1,000 mm and 1,250 mm, such as approximately 1,200 mm, and the length of the inner beam component may be in a range between approximately 300 mm and 600 mm, such approximately as 400 mm. In some examples, such as in bumper components extended for small overlap impact testing, the outer beam component may have a length in a range between 1,500 mm and 1,600 mm. These ranges are inclusive of the respective endpoints.

As shown inFIG.3, the lateral end sections38a,38bof the outer beam component that are disposed at opposing ends of the central section24are void of the inner beam component22. The lateral end sections38a,38b, however, undergo less bending stress than the central section24due to the support of the outer beam component20provided by the crush cans14at the lateral end sections38a,38b. Thus, the reinforcement provided by the inner beam component22is not provided at the lateral end sections38a,38b. It is understood that the reinforcement beam may be longer in additional examples and that the impact location may vary from a central section, such as in other implementations on the vehicle.

As illustrated inFIG.4A, the bumper reinforcement beam12includes a generally straight shape along the length of the beam12. Each of the beam components forming the reinforcement beam12has a corresponding straight shape to provide secure mating of the components together along the length of the beam. In other examples as shown inFIG.4B, the bumper reinforcement beam12includes a curved shape or sweep that is imparted along the length of the beam12. Such a curved shape or sweep may generally conform the beam to the package space permitted by the vehicle design. The curved shape may have a consistent radius of curvature along the length of the bumper reinforcement beam, such as shown inFIG.4B, or in additional examples may have a varied radius of curvature at different sections of the length, such as a greater curvature (and effectively a smaller radius of curvature) at the lateral end sections of the beam. As further illustrated inFIG.4B, each of the beam components forming the bumper reinforcement beam12have a corresponding curved shape so as to provide a secure mating of the components together on the length of the reinforcement beam. The corresponding curved shape between the beam components shown inFIG.4Bis provided by the same or substantially similar radius of curvature for each beam component.

As illustrated in the example inFIGS.5and6, the outer beam component20has an elongated hollow body formed from a metal sheet material, such as a front sheet or piece26and a rear sheet or piece28that are attached together. In other words, the front piece26of the outer beam component20is an outboard beam component26and the rear piece28is an inboard beam component28. The front and rear pieces26,28are coupled together at their respective upper flanges40a,42aand lower flanges40b,42b. The front and rear pieces26,28may be coupled, for example, directly or indirectly through mechanical joining such as via welding adhesive, or the like. As shown inFIG.5, the front piece26has an upper flange40aextending upward beyond the hollow interior area44defined by the outer beam component20and a lower flange40bextending downward beyond the hollow interior area44defined by the outer beam component20. The upper and lower flanges40a,40bof the front piece26extend vertically in planar extension of the front wall30of the front piece.

As also shown inFIG.5, the rear piece28has an upper flange42aextending upward beyond the hollow interior area44defined by the outer beam component20and a lower flange42bextending downward beyond the hollow interior area44defined by the outer beam component20. The upper and lower flanges42a,42bof the front piece26also extend vertically so as to position a forward mating surface to receive a rear mating surface of the upper and lower flanges40a,40bof the front piece26. The upper flanges40a,42aand the lower flanges40b,42bengage together to form a flange connection with the sheets overlapping at the upper and lower front corners of the outer beam component20, protruding vertically above and below the hollow interior area44enclosed by the outer beam component20.

The rear piece28of the outer beam component20, as shown inFIG.5, includes an upper wall48and a lower wall50that together with the rear wall32define a C-shaped cross section. The upper flange42aof the rear piece28integrally extends upward from the forward portion of the upper wall48. Likewise, the lower flange42bof the rear piece28integrally extends downward from the forward portion of the lower wall50. Accordingly, the example shown inFIG.5provides a depth D to the outer beam component20of the overall reinforcement beam12that that is defined by the length of the upper and lower walls48,50of the outer beam component20. The depth D of the section is constant along the length of the reinforcement beam12and is generally proportional to the other features. In the example shown, the depth is approximately 40 mm and in additional examples may be between 50 mm and 70 mm or more or less. The rear wall32of the outer beam component20shown inFIGS.5and6has two rear ribs47that extend along the length of the outer beam component. In additional examples, there may be more or fewer rear ribs and the rear ribs may have different shapes, dimensions, and positions on the rear wall. Also, the rear ribs47have a height vertically on the rear face and depth forward from the rear face of the rear wall32that is configured to allow the sheet material to be formed inward in a generally curved shape without exceeding the allowable curvature (minimum capable bending radius) of the sheet material without failure. The rear ribs47provide additional stiffness to the rear wall32. In other examples, the rear wall32is void of rear ribs47(FIG.8). For example, the beam assembly may have a height of less than 80 mm. In some instances, the rear ribs47may not be provided.

Referring again to the front piece26, the front wall30of the outer beam component20shown inFIGS.5and6has two front ribs46that extend along the length of the outer beam component. In additional examples, there may be more or fewer front ribs and the front ribs may have different shapes, dimensions, and positions on the front wall. Also, the front ribs46have a height vertically on the front face and depth rearward from the front face of the front wall30that is configured to allow the sheet material to be formed inward in a generally curved shape without exceeding the allowable curvature (minimum capable bending radius) of the sheet material without failure. The front ribs46provide additional stiffness to the front wall.

The metal sheet material of the outer beam component can comprise of any metals or metal alloys that have the desired characteristics, such as stiffness, tensile strength, and the like. For example, the material may include aluminum or steel, such as a high strength or ultra-high strength steel, as well as combinations of other related metals in different alloys. For example, an ultra-high strength steel is one with an ultimate tensile strength of greater than 780 MPa, or in some examples greater than 1,000 MPa. The sheet material of the outer beam component may be formed in various processes, such as with the use of cold stamping, roll forming, roll stamping, hot stamping, press brake bending, or combinations thereof.

As further shown inFIGS.5and6, the inner beam component22is provided to reinforce the hollow area44between the front wall30and the rear wall32of the outer beam component20by providing an upper wall34and a lower wall36that extend between the front and rear walls30,32. The upper and lower walls may also be referred to as shear walls and may be configured to undergo axial loading from impact forces to the bumper system. The inner beam component22may have a greater bending strength than the outer beam component20, such as a result, at least in part, of forming the inner beam with a metal sheet having a greater thickness. For example, the inner beam component22may be formed from a different metal sheet material having a greater thickness than the metal sheet material of the outer beam, such as twice the thickness or more or less. In the example shown inFIG.5, the thickness of the metal sheet forming the inner beam component22is approximately 2 mm and the thickness of the metal sheet forming the outer beam component20is approximately 1 mm. As such, the thickness of the metal sheet forming the inner beam component may be 2 times or 2.5 time or greater that of the outer beam component. In additional examples, the inner beam component has a thickness greater than 1.2 mm, or greater than 1.5 mm, or greater than 1.8 mm.

The inner beam component22, as shown inFIGS.5and6, has an intermediate portion or connecting wall52that integrally interconnects between the upper wall34and the lower wall36to define a channel or C-shape along the inner beam component22. As shown inFIG.5, the intermediate portion52has a planar shape that abuts the inner surface of the outer beam component20to provide an interfacing surface area. The intermediate portion52of the inner beam may be attached to the front wall30of the outer beam component20, such as via adhesive, welding, fasteners, or the like. Also, in some instances, the intermediate portion52of the inner beam may contact the front wall30of the outer beam component20without any positive attachment. In additional examples, such as shown inFIG.8, the intermediate portion152may have a groove154that is formed along a forward surface of the inner beam component22(FIG.8). The groove154, like the ribs on the front wall, can also provide additional stiffness and support to the front portion of the bumper reinforcement beam.

The upper and lower walls34,36of the inner beam component22may divide the hollow interior area44of the hollow body formed by the outer beam component20to form a plurality of elongated hollow areas44′,44″,44″' (FIG.5). In doing so, the height of the intermediate portion52of the inner beam component22is configured for the ribs46in the front wall30to be generally centered over the respective upper and lower hollow areas44′,44′. The upper and lower walls34,36of the inner beam component22extend rearward at an angle α relative to normal or perpendicular to the planar extent or vertical orientation of the front wall30, or in some examples the angle α is defined as relative to a generally horizontal plane. In some examples, the angle α is less than 40 degrees and preferably between −5 and 20 degrees. In other examples, the angle α for the upper wall of inner beam extends rearward and upward at less than 20 degrees relative to normal to a planar extent of the front wall. In some examples, the angle α for the lower wall of inner beam extends rearward and downward at an angle of less than 20 degrees relative to normal to a planar extent of the front wall. It is also contemplated that the angle may be 12 degrees, between 10 and 12 degrees, between 8 and 12 degrees, between 5 and 15 degrees, between 0 and 15 degrees, or between −5 and 20 degrees. In examples with rear ribs47positioned on the rear wall32, the angle α may be between 8 and 12 degrees. For example, the angle α may be 10 degrees when rear ribs47are included. In examples where the rear wall32is void of rear ribs47, the angle α may be larger, such as 20 degrees.

Further, as shown inFIGS.5and6, the inner beam component22has rear flanges56a,56bthat integrally extend from the upper and lower walls34,36. As shown inFIG.5, the upper rear flange56aextends upward from the upper wall34and the lower rear flange56bextends downward from the lower wall36. In some examples, the rear flanges56a,56bare coupled to the rear wall32of the outer beam component20, such as via welding, adhesive, fasteners, or the like. In other example, the rear flanges are not coupled to the rear wall32. In some instances, the upper rear flange56aand the lower rear flange56bextend to a position adjacent to the rear ribs47of the rear wall32. In such position, the rear ribs47may be configured to retain the upper and lower flanges56a,56b, such as to prevent vertical movement of the inner beam component22relative to the outer beam component20within the hollow interior area44.

While the thickness may be greater than the sheet material of the outer beam component20, the metal sheet material of the inner beam component22can comprise the same metal, such as any metals or metal alloys that have the desired characteristics, such as stiffness, tensile strength, and the like. For example, the material may include aluminum or steel, such as a high strength or ultra-high strength steel, as well as combinations of other related metals in different alloys. Also, in other examples, the sheet material of the inner beam component may include a greater stiffness than the outer beam component, such as with a small, equal, or larger thickness. Further, the sheet material of the inner beam component22can also be formed in various processes, such as with the use of cold stamping, roll forming, roll stamping, hot stamping, press brake bending, or combinations thereof.

In addition, or in the alternative, the inner beam component22may be entirely or partially made of a non-sheet material, such as an injection molded polymer or composite, an aluminum extrusion, or a composite pultrusion, or the like. With the incorporation of such an alternative material structure for the inner beam component22, the geometry may also be different from the geometry of the inner beam component22shown inFIGS.5and6. In such further alternatives, the inner beam component22or features thereof may be formed via machining, molding, or other process suitable to the material selected for forming the alternative material.

Referring now toFIG.7, simulated experimental test results are illustrated showing the rearward displacement of the bumper reinforcement beam12in millimeters (mm) upon the application of increasing force load when undergoing a center pole impact test. The graph inFIG.7illustrates the results of a simulated test where the bumper reinforcement beam12illustrated inFIG.8is compared to known bumper reinforcement beam designs that are proportioned to have the same mass as the tested bumper reinforcement beam. The results show an increase in strength of 36% (at peak loading) and an increase in energy absorption of 92% after displacement of 100 mm. To obtain a similar level of performance, the other bumper reinforcement beam designs would generally need to have an additional mass of approximately 25%.

Additional examples of reinforcement beams are illustrated inFIGS.8-20, showing various alternative features and variations from the reinforcement beam shown inFIGS.5and6. For example,FIGS.8and9illustrate reinforcement beams112,212with alternative rib structures as described above. For instance,FIG.8illustrates a reinforcement beam112with an outer beam component120having a rear piece128void of rear ribs to form a substantially planar rear wall132and a front piece126having a front wall130.FIG.8also illustrates the inner beam component122including the groove154positioned on an intermediate portion or connecting wall152interconnected between the top wall134and the bottom wall136.

FIG.9illustrates the reinforcement beam212provided with an outer beam component220having a front piece226without ribs, so as to form a substantially planar front wall230, although it may have a curved shape or sweep along its length. The outer beam component includes a rear piece228without ribs, so as to form a substantially planar rear wall232. The inner beam component222includes a groove254positioned on an intermediate portion or connecting wall252interconnected between the top wall234and the lower wall236.

In the example shown inFIG.10, the reinforcement beam312has a common sheet thickness for the pieces of the outer beam component320and the inner beam component322. With a small sheet thickness for the inner beam component322, the upper and lower walls334,336are closer together, and the transition bends at the forward portion of the upper and lower walls can have a smaller radius of curvature and thereby a shorter height at the intermediate portion352. In the illustrated example, the outer beam component322includes a rear piece328without ribs, so as to form a substantially planar rear wall332and a front piece326with ribs forming a front wall330.

Similarly, in the example shown inFIG.11, the reinforcement beam412has a common sheet thickness, but instead of 1 mm as shown inFIG.10, the reinforcement beam412has a thickness of 2 mm which results in forming larger heights of the ribs446on the front wall430without exceeding the allowable curvature (minimum capable bending radius) of the sheet material without failure. In the illustrated example, the outer beam component422includes a rear piece428without ribs, so as to form a substantially planar rear wall432and a front piece426with ribs forming a front wall430.

As shown inFIGS.12, the inner beam component522of the reinforcement beam512is similarly reduced in height to the example shown inFIG.10, but to a greater degree. This shorter height of the inner beam component522is again attributable to the inner beam component having a thinner sheet material with, in turn, a greater degree of bending. In the illustrated example, the outer beam component522includes a rear piece528without ribs, so as to form a substantially planar rear wall532and a front piece526with ribs forming a front wall530.

The example shown inFIG.13, alters the inner beam component622from the reinforcement beam shown inFIGS.5and6by reversing the rear flanges656a,656bthat integrally extend from the upper and lower walls634,636. As shown inFIG.13, the upper rear flange656aextends downward from the upper wall634and the lower rear flange656bextends upward from the lower wall636. In the illustrated example, the outer beam component622includes a rear piece628without ribs, so as to form a substantially planar rear wall632and a front piece626with ribs forming a front wall630.

With reference to the examples of the reinforcement beams712,812shown inFIGS.14and15, these each shorten the height of the front wall730,830by eliminating the upper and lower flanges extending beyond the profile of the hollow interior area. Instead, the front piece726,826is coupled to the rear piece728,828of the outer beam component720,820by attaching the upper and lower edges of the front piece726,826to inward protruding front flanges742a,842aon the rear piece728,828. Specifically, as shown inFIG.14, the front piece726is attached to the rear-facing surface of the front flanges742aof the rear piece728. Alternatively, as shown inFIG.15, the front piece826is attached to the front-facing surface of the front flanges842a,842bof the rear piece328.

Further examples of the reinforcement beam are shown inFIGS.16-19that integrate and eliminate different walls, such as by using a single sheet that is roll formed or otherwise bent to form such different shapes. As shown inFIGS.16and17, a single sheet is used to bend the reinforcement, such that the upper and lower walls of the inner beam component are integrally part of the same metal sheet as the outer beam component. Specifically, inFIG.16, the reinforcement beam912includes an outer portion920having a rear piece928which forms a generally c-shaped component. The rear piece928is void of ribs to form a substantially planar rear wall932. The outer portion920includes a front piece926including a front wall930which includes ribs. The sheet that defines the outer beam component920further defines the inner beam component922. The inner portion922extends inward in front of the rear wall932portion and includes a top wall934and a rear wall936which extend between the front wall930and the rear wall932of the outer portion920.

Similarly toFIG.17, a single sheet is used to define both the outer portion1020and the inner portion1022of the reinforcement beam1012. Instead, however, the outer portion1020includes a rear piece1028further including a rear wall, which includes a central rib1032that follows the C-shape of the inner portion1022, specifically following the top wall1034and the lower wall1036of the inner portion1022.

InFIG.18, the reinforcement beam1112includes an inner beam component1122configured as a separate piece and provided as a rear reinforcement along portions of the upper and lower walls1134,1136of a rear wall rib1132. Similarly and as illustrated inFIG.19, a reinforcement beam1212may include the outer beam component used along without the inner beam component1122ofFIG.18.

In yet another example as shown inFIG.20, the reinforcement beam1312may also include an inner beam component1322that has a wave shape along its length, with the wave shape being formed in the upper and lower walls1334,1336in the z-direction. Such wave shape formations may provide increased stability along the upper and lower walls in undergoing stress and receiving impact loads.

In another example as shown inFIGS.21-23, the reinforcement beam1412includes an inner beam component1422that has tapered ends1460,1462. The inner beam1422includes a front facing side1452or intermediate or connecting wall that connects the upper wall1434and the lower wall1436. The front facing side1452runs adjacent to and generally parallel to the front wall1430of the outer beam. The inner beam1422also includes a rear facing side1464that generally includes the rear most portion of the upper wall1434and the lower wall1436. The front facing side1452has a length longer than a length of the rear facing side1464. The tapered ends1460,1462connect the ends of the front facing side1452to the respective ends of the rear facing side1464of the inner beam component1422defining a tapered shape due to the difference in the length. As shown inFIG.23, the tapered ends1460,1462are angled at approximately 45 degrees relative to the front wall1430, such that the front facing side1452has a longer length than the rear facing side1464. The tapered shape of the ends1460,1462may provide a gradual reduction in stress concentration upon impact and a reduction in strength at the ends of the inner beam component1422. A gradual reduction in strength may provide increased stability along the beam1412in undergoing stress and receiving impact loads.

Similarly as shown inFIGS.24-26, the reinforcement beam1512includes an inner beam component1522that has tapered ends1560,1562. The inner beam1522includes a front facing side1452or intermediate or connecting wall that connects the upper wall1534and the lower wall1536. The front facing side1552runs adjacent to and generally parallel to the front wall1530of the outer beam. The inner beam1522also includes a rear facing side1564that generally includes the rear most portion of the upper wall1534and the lower wall1536. The tapered ends1560,1562connect the ends of the front facing side1552to the respective ends of the rear facing side1564of the inner beam component1522defining a tapered shape due to the difference in the length. As shown inFIG.26, the tapered ends1560,1562are angled at approximately 45 degrees relative to the front wall1530, such that the front facing side1552has a longer length than the rear facing side1564. The tapered shape of the ends1560,1562may provide a gradual reduction in stress concentration upon impact and a reduction in strength at the ends of the inner beam component1522. A gradual reduction in strength may provide increased stability along the beam1512in undergoing stress and receiving impact loads.

For purposes of this disclosure, the term “coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature; may be achieved with the two components (mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components; and may be permanent in nature or may be removable or releasable in nature, unless otherwise stated.

The articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements in the preceding descriptions. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional implementations that also incorporate the recited features. Furthermore, the terms “first,” “second,” and the like, as used herein do not denote any order, quantity, or importance, but rather are used to denote element from another.

Numbers, percentages, ratios, or other values stated herein are intended to include that value, and also other values that are “about” or “approximately” the stated value, as would be appreciated by one of ordinary skill in the art encompassed by implementations of the present disclosure. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result. For example, the terms “approximately,” “about,” and “substantially” may refer to an amount that is within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of a stated amount.

Further, it should be understood that any directions or reference frames in the preceding description are merely relative directions or movements. For example, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” “inboard,” “outboard” and derivatives thereof shall relate to the orientation shown inFIG.1. However, it is to be understood that various alternative orientations may be provided, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in this specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

Changes and modifications in the specifically described embodiments may be carried out without departing from the principles of the present invention, which is intended to be limited only by the scope of the appended claims as interpreted according to the principles of patent law. The disclosure has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present disclosure are possible in light of the above teachings, and the disclosure may be practiced otherwise than as specifically described.