Rocker assembly insert with opposed crush channels

A vehicle rocker assembly includes an outer sill member and an inner sill member attached longitudinally along the outer sill member to define a hollow space along and between the inner and outer sill members. A tubular insert is disposed in the hollow space so as to extend longitudinally along the hollow space. The tubular insert has a crush control feature extending longitudinally along a wall of the tubular insert, such as upper and lower walls at opposing sides of the interior volume. The tubular insert is configured for side impact forces at the outer sill member to laterally deform the tubular insert at the crush control feature to provide an accordion-style lateral crush to absorb the side impact forces.

TECHNICAL FIELD

The present disclosure relates to rocker and sill assemblies for vehicles, such as rocker structures having reinforcement inserts.

BACKGROUND

Vehicles typically have a rigid frame and body structure, which is commonly referred to as a unibody frame. The vehicle frame and body structures are designed to support the vehicle during operation and to undergo and absorb certain levels of impact forces, such as to prevent distances of intrusion to the vehicle cabin, trunk, engine compartment, or the like in accordance with insurance requirements and other regulatory and legal requirements. With respect to impact reinforcement and structural beams used in a vehicle body or frame, it is generally known that these beams may be reinforced with interior inserts to increase stiffness. Rocker assemblies extend longitudinally along lower portions of unibody vehicle frames and are known to have inserts to increase stiffness, such as to reduce side impact intrusion.

SUMMARY

The present disclosure provides a rocker assembly for a vehicle body frame that includes a hollow external structure formed with attached inner and outer sill members. A reinforcement insert is disposed within and extends longitudinally along an interior space of the hollow external structure. The reinforcement insert has a cross-sectional profile that is generally consistent along a length of the rocker assembly, such as to provide a tubular shape with one or more enclosed tubular sections. The reinforcement insert may be roll-formed, stamped, or extruded to have the consistent cross-sectional profile, such as the closed or otherwise tubular cross-sectional shape. To increase impact energy absorption from side impact forces delivered to the outer sill member, such as a side pole impactor, the reinforcement insert is provided with one or more lateral crush control features. The crush control features assist with controlling the lateral compression and deformation of the rocker assembly while undergoing impact forces, such as by causing the side impact forces to laterally deform the tubular insert in an accordion-style lateral crush. The crush control features may be provided as crush channels formed along the reinforcement insert, such as to protrude into an interior volume of a tubular shape. The crush channels may be arranged at opposing sides of the reinforcement insert, such as at upper and lower walls of an enclosed tubular section of the reinforcement insert, for side impact forces to laterally deform the tubular insert at the crush channels and provide an inward or outward folded deformation, such as an accordion-style lateral crush.

According to one aspect of the present disclosure, a vehicle rocker assembly includes an outer sill member and an inner sill member attached longitudinally along the outer sill member to define a hollow space along and between the inner and outer sill members. A tubular insert is disposed in the hollow space so as to extend longitudinally along the hollow space. The tubular insert has an upper wall and a lower wall that border opposite sides of an interior volume of the tubular insert. The upper wall and/or lower wall of the tubular insert has a crush channel extending longitudinally along the tubular insert. The crush channel or channels are configured for side impact forces at the outer sill member to laterally deform the tubular insert to provide an accordion-style lateral crush to at least partially absorb the side impact forces.

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

In some implementations, the crush channel or channels protrude into the interior volume of the tubular insert, and with two or more channels may be disposed at the upper and lower walls at opposing sides of the interior volume. In some examples, the crush channels may be are mirrored across the interior volume of the tubular insert, such as at the outer tubular section or the inner tubular section. In other examples, the crush channels are vertically staggered relative to each other. Further, the upper and lower walls of the tubular insert may be disposed in planar parallel alignment with each other or may have a tapered shape. The crush channels in some examples are vertically aligned across the interior volume of the outer tubular section, such as perpendicularly relative to the upper and lower walls. The crush channels of the tubular insert may be configured to simultaneously deform under the side impact forces at the outer sill member.

With respect to fixation of the tubular insert, a bracket may be attached between upper flanges of the outer and inner sill members, where the bracket is attached to and supporting the tubular insert in the hollow space. Also, in some implementations, the tubular insert includes a flange that is attached between upper flanges of the outer and inner sill members, where the flange supports the tubular insert in the hollow space. Further, the tubular insert may be fixed at an interior surface of the outer sill member or the inner sill member, such as via at least one of a weld, a fastener, or an adhesive.

In some examples, the tubular insert comprises a metal sheet formed to have an outer tubular section and an inner tubular section that share a common center wall, the outer and inner tubular sections disposed laterally adjacent to each other. Alternatively, the tubular insert may be longitudinally extruded to have an outer tubular section and an inner tubular section that share a common wall that integrally interconnects with the upper and lower walls of the tubular insert.

DETAILED DESCRIPTION

Referring now to the drawings and the illustrative embodiments depicted therein, a reinforced rocker assembly10is provided for a body structure or frame102of a vehicle100, such as shown inFIGS.1and2. The vehicle frame and associated rocker assembly may have various designs and configurations, such as for different styles and types of vehicles. As shown for example inFIG.1, the vehicle100may at least partially operate a propulsion system of the vehicle with a battery, such as a traction battery or battery modules, that may be supported in a battery tray104generally located between the axles and near the floor of the vehicle100to distribute the battery weight and establish a low center of gravity for the vehicle.

The vehicle rocker assembly10, as shown for example inFIGS.3-4B, includes a hollow external structure12that is formed with an inner sill member14and an outer sill member16, which can also be referred to as a rocker panel or section. The inner sill member14is attached longitudinally along the outer sill member16to define an elongated hollow space18between the inner and outer sill members14,16. The inner and outer sill members14,16that form the external structure12surround the elongated hollow space18between the inner and outer sill members14,16. A reinforcement insert20is disposed in the hollow space18of the external rocker structure12and extends longitudinally along at least a portion or longitudinal section of the hollow space18. The reinforcement insert20has a cross-sectional profile that is generally consistent along its length, such as a tubular shape with one or more enclosed tubular sections. As such, the reinforcement insert20may be referred to as a tubular insert.

The reinforcement insert20is provided with one or more lateral crush control features to increase impact energy absorption by controlling lateral compression and deformation of the rocker assembly10undergoing side impact forces delivered to the outer sill member, such as forces delivered by a side pole impactor. For example, as shown inFIGS.3-4A, crush channels22are disposed along opposing upper and lower sides of the reinforcement insert20. The crush channels22are arranged to allow for the reinforcement insert20to crush laterally like an accordion. This type of accordion-style crush can limit cracking and material failures by controlling how the section crushes. The controlled crush provided by the crush channels22also adds to the material stack up later in the event, leading to more energy absorption overall.

It is contemplated that the reinforcement insert of the disclosed rocker assembly may be incorporated in other types of structural beams, such as in frames and structures of automotive and other vehicles. Also, the reinforcement insert may be used in other structural frame components and in impact energy management beams that are configured to undergo impact loads at various sections of the beam and absorb such impact loads in a desirable manner. For example, as shown inFIG.2, a frame102of a vehicle100has multiple structural beams, one or all of which may be provided with internal reinforcements as described herein.

To form the external structure12, the inner sill member14has an upper flange14aattached along an upper flange16aof the outer sill member16. The inner sill member14also has a lower flange14bof the inner sill member14attached along a lower flange16bof the outer sill member16. Such attachment of the inner and outer sill members14,16may be a direct contact engagement or may be indirectly attached with an intermediary, such as a flange, plate, or bracket, sandwiched between the upper and lower flanges14a,14b,16a,16b. As shown inFIGS.3-4B, the upper and lower flanges14a,14b,16a,16bare provided along the upper and lower edges of the respective inner and outer sill members14,16. The upper and lower flanges14a,14b,16a,16bare also substantially planar and oriented in a generally vertical configuration, such as to attach in direct contact along sections of the length of the rocker assembly10(FIG.4A) and to also attach indirectly at discrete sections, where support brackets62are arranged between the flanges (FIG.4B). The upper and lower flanges14a,14b,16a,16bare attached together via welding, although adhesive and/or mechanical fasteners may be used in addition or in the alternative to welding in other examples of the rocker assembly. The inner and outer sill members14,16shown inFIG.3are steel, although it is contemplated that other examples may include alterative or multiple materials, such as steel, aluminum, and/or composites.

The intermediate portions of the inner and outer sill members14,16are generally provided between the upper and lower flanges14a,14b,16a,16band are shaped with a generally concave transverse cross-sectional shape, such as the exemplary C-shaped sections of the inner and outer sill members14,16shown inFIGS.4A and4B. The intermediate portion of the inner sill member14has an upper wall section24, an innermost wall section26, and a lower wall section28that are each generally planar in shape. Similarly, the intermediate portion of the outer sill member16has an upper wall section30, an outermost wall section32, and a lower wall section34that are each generally planar in shape. As shown inFIGS.4A and4B, the upper wall sections24,30have a substantially equal length to the corresponding lower wall sections26,34. Also, the upper and lower wall sections24,26,30,34are angled from a horizontal orientation, with each pair of upper and lower wall sections similarly angled. As a result of the substantially equal lengths and angles, the upper and lower flanges14a,14b,16a,16bshown inFIGS.4A and4Bare vertically aligned with each other. In other examples, such as shown inFIG.8A, the upper and lower flanges of the external structure may be offset from each other. Also, the cross-sectional profile of the inner and outer panels14,16may be generally consistent along the length of the rocker assembly, such as shown in the examples shown inFIGS.3-6, or may be have some inconsistent features along the lengths, such as to accommodate door pillar engagement as shown in the example inFIGS.7and8.

As shown inFIGS.3-4B, the reinforcement insert20is disposed within the elongated hollow space18, extending longitudinally along the entire length of inner sill member14and along a portion of the length of the outer sill member16. In other examples, the reinforcement insert may extend along a different longitudinal extent of the hollow external structure, such as within or beyond the lengths of the outer and inner sill members. The crush control features of the reinforcement insert20may be integrally formed in the reinforcement insert20, such as the crush channels22that extend consistently along the length of the reinforcement insert20. As shown inFIGS.4A and4B, the crush channels22protrude into an interior volume36of both tubular shapes of the reinforcement insert20. However, it is also contemplated that one or more crush channels may protrude outward along the upper or lower wall of the reinforcement insert away from the interior volume. Also, as shown inFIGS.4A and4B, the crush channels22are arranged at opposing sides of the interior volume36for side impact forces to laterally deform the reinforcement insert20inward at the crush channels22, such as to provide an accordion-style lateral crush pattern. In other examples, a single crush channel may be provided or additional crush channels may be utilized. The crush channels may be arranged at the upper and lower walls of the outer tubular section without crush channels in the other tubular section or sections, or alternatively, the crush channels may instead be disposed at the upper and lower walls of the inner tubular section without crush channels in the outer tubular section or sections, such as shown inFIG.8A.

The crush channels in some examples are configured to simultaneously deform under the side impact forces at the outer sill member. For example, as shown inFIGS.4A and4B, the crush channels22are disposed at opposing sides of the reinforcement insert in an alignment that is generally perpendicular to the orientation of a horizontal side impact force. As such, the crush channels22may be mirrored across the interior volume of the outer and inner tubular sections so as to be vertically aligned with each other for optimized crush as a result of a horizontal side impact force. In other examples, the crush channels may be disposed in a laterally staggered alignment from each other, such as laterally staggered from each other across an enclosed interior volume or staggered with the crush channels arranged at separate tubular sections of the reinforcement insert.

The reinforcement insert20has an upper wall38and a lower wall40that border opposite sides of an interior volume36of the reinforcement insert20. As shown inFIGS.4A and4B, the upper and lower walls38,40of the reinforcement insert20are disposed in planar parallel alignment with each other. In other examples, the upper and lower walls may be tapered or angled toward or away from each other or may have a non-planar shape, such as a curved or rounded transition along the width of the respective wall. The upper and lower walls38,40of the reinforcement insert20each have a crush channel22protruding into the interior volume36and extending longitudinally along the respective upper and lower walls at opposing sides of the interior volume36. Again, in other examples, one or more crush channel may protrude outward from the interior volume. As also shown inFIGS.4A and4B, the reinforcement insert20includes an outer tubular section42and an inner tubular section44integrally formed together and disposed laterally adjacent to each other. The outer tubular section42and the inner tubular section44share a common center wall46that extends vertically between the upper and lower walls38,40of the reinforcement insert20and divides the interior volumes of the respective outer and inner tubular sections42,44.

As further shown inFIGS.4A and4B, the outer tubular section42of the reinforcement insert20has an outer wall48that is integrally interconnected between the upper and lower walls38,40of the reinforcement insert20. The outer wall48faces the outermost wall section32of the outer sill member16and contacts the outermost wall section32. Similarly, the inner tubular section44has an inner wall50integrally interconnected between the upper and lower walls38,40of the reinforcement insert20. The inner wall50faces the innermost wall section26of the inner sill member14and contacts the innermost wall section26. Thus, the reinforcement insert may have a lateral width between the inner and outer walls that is sized to fit tight or occupy the distance between the inner sill and the outer sill, such as shown inFIGS.4A and4B. In other examples, however, the reinforcement insert may fit tight to only one of the inner and outer sill members and be gapped to the other side, or alternatively may be designed with a gap on both sides, so as to float in the space between the inner and outer sill members. Also, although the reinforcement insert20shown inFIGS.4A and4Bis spaced from the upper wall sections24,30and the lower wall sections28,34, it is contemplated that the spacing may be reduced or generally eliminated due to the ability of the crush control features to causes inward deformation upon lateral impact forces at the outer side of the rocker assembly, such as to deform in an accordion shape within the exterior structure of the rocker assembly.

To form the tubular insert20shown inFIGS.3-4B, a metal sheet is roll formed to have the outer tubular section42and the inner tubular section44laterally adjacent to each other, sharing the common center wall46. The outer sections of the metal sheet that form the two adjacent tubular sections extend from opposing sides of a center section of the metal sheet that forms the common center wall46. As oriented inFIGS.3-4B, the two adjacent tubular sections14,16are defined on opposing sides of the common center wall46by the upper walls52,54, the lower walls56,58, an outer wall48, and an inner wall50. The crush channels22are roll formed into the metal sheet at the upper walls52,54and the lower walls56,58. The crush channels22have a width of about 10%-40% of a width of the corresponding wall section (or more preferably about 20%-30% of the wall width) and has a depth about equal to the width dimension. As shown inFIGS.4A and4B, the illustrated crush channels20are semicircular shaped. It is also contemplated that a depth and size of the crush channels can be made shallow, deeper, wider, narrower, or otherwise modified for the desired lateral crush characteristics.

The metal sheet used to form the reinforcement insert inFIGS.4A and4Bis a steel material, such as an advanced high strength steel (AHHS), having a thickness of 0.8 mm to 1.4 mm or approximately between 1 mm and 1.5 mm. Also, the sheet12may have a tensile strength of about 800 to 2000 MPa (i.e. about 120 to 290 ksi). It is also contemplated that the reinforcement insert can be made of a sheet having a different thickness and may be made with one or a combination of different materials, such as steel, aluminum, and/or a composite.

To hold the roll formed sheet in the tubular shape of the reinforcement insert20, one edge60aof the sheet is attached via welding to a lower end of the center wall46and the other edge60bis attached via welding to the upper wall52near the upper end of the center wall46. The upper walls52,54and lower walls56,58of the adjacent tubular sections42,44are substantially aligned with each other to form the respective upper and lower walls38,40of the reinforcement insert. Further, the outer and inner walls28,30are substantially parallel with each other and the common center wall18and generally perpendicular with the upper and lower walls20,22,24,26. Additional examples of the reinforcement insert may assume various shapes and orientations from that shown inFIGS.4A and4Band may include alternatively dimensional proportions, such as for different applications of the insert.

The reinforcement insert may be supported and/or attached within the external structure in various ways. For example, a series of brackets62(FIG.4B) are attached between the upper and lower flanges14a,14b,16a,16bof the outer and inner sill members14,16spaced along the length of the reinforcement insert. As shown inFIG.4B, the brackets62have an L-shape with inner portion64attached to the upper and lower walls38,40and an outer portion66attached with welding between the upper and lower flanges14a,14b,16a,16bto support the reinforcement insert20in the hollow space18. In other examples, the reinforcement insert may also or alternatively be attached at an interior surface of the outer sill member or the inner sill member, such as via a weld, a fastener, and/or an adhesive.

Referring toFIGS.5-6B, the reinforcement insert120is disposed within the hollow space118, extending longitudinally along the entire inner sill member114and along a portion of the outer sill member116. The crush channels122of the reinforcement insert120are integrally formed in the reinforcement insert120and extend consistently along the length of the reinforcement insert120. As shown inFIGS.6A and6B, reinforcement insert120is longitudinally extruded, such as with an aluminum alloy, to have an outer tubular section142and an inner tubular section144that share a common wall146integrally interconnecting between the upper and lower walls138,140of the reinforcement insert120. The upper wall138and the lower wall140that border opposite sides of the interior volume136of the reinforcement insert120and are disposed in planar parallel alignment with each other. The crush channels122are extruded into the upper and lower walls138,140to extend into an interior volume136of the respective tubular shapes of the reinforcement insert120. The crush channels122shown inFIGS.6A and6Bhave a V-shape to assist with initiating the lateral crush of the reinforcement insert at the crush channels. The crush channels122are arranged at opposing sides of the interior volume136for side impact forces to laterally deform the reinforcement insert120inward at the crush channels122, such as to provide an accordion-style lateral crush pattern.

As shown inFIGS.6A and6B, reinforcement insert120includes an outer tubular section142and an inner tubular section144integrally formed together and disposed laterally adjacent to each other. The crush channels122are mirrored across the interior volumes136of the outer and inner tubular sections142,144, so as to be vertically aligned with each other. As also shown inFIGS.6A and6B, the outer tubular section142of the reinforcement insert120has an outer wall148that is integrally interconnected between the upper and lower walls138,140of the reinforcement insert120. The outer wall148faces the outermost wall section132of the outer sill member116and contacts the outermost wall section132. Similarly, the inner tubular section144has an inner wall150integrally interconnected between the upper and lower walls138,140of the reinforcement insert120. The inner wall150faces the innermost wall section126of the inner sill member114and contacts the innermost wall section126.

To support the reinforcement insert120within the external structure112, a series of brackets162are attached between the upper and lower flanges114a,114b,116a,116bof the outer and inner sill members114,116. As shown inFIG.6B, the brackets162have an L-shape with inner portion164attached to the upper and lower walls138,140and an outer portion166attached between the upper and lower flanges114a,114b,116a,116bto support the reinforcement insert120in the hollow space118. The attachment of the bracket to the reinforcement insert and the external structure may be done with a weld, a fastener, an adhesive, and/or a material intermediary, such as in a manner to prevent galvanic corrosion.

Also, in some implementations, the reinforcement insert may include a flange that is attached between upper flanges of the outer and inner sill members, where the flange attaches to the external structure of the rocker assembly to support the tubular insert in the hollow space of the external structure. As shown inFIG.8A, the reinforcement insert220includes an upper flange portion270that integrally extends upper ward from the crushable insert portion268and a lower flange portion272that integrally extends downward from the crushable insert portion268. The upper and lower flange portions270,272attach between the respective upper and lower flanges214a,214b,216a,216bof the inner and outer sill members214,216edges or flanges of the panels212,214to secure the reinforcement insert220relative to the inner and outer sill members214,216. For example, the flange portions are spot welded between the first and second panels214,216, although with alternative welding methods or different attachment means may be used, such as adhesive, mechanical fasteners, or combinations thereof. In other implementations, an integral flange of the reinforcement insert may also be used to attach to the vehicle frame or other component parts.

With further reference toFIGS.7-8A, the reinforcement insert220is roll formed from a metal sheet to provide the crushable insert portion268and the upper and lower flange portions270,272as integral sections of the metal sheet, so as to extend longitudinally and continuously along a length of the reinforcement insert220. The upper and lower flange portions270,272of the reinforcement insert220are provided at edge portions of the metal sheet. As shown inFIG.8A, the wall sections of the crushable insert portion268include a common center wall246dividing two adjacent tubular sections214,216, upper walls252,254, lower walls256,258, an outer wall248, and an inner wall250. The crush channels222are roll formed into the metal sheet at the upper walls252,254and the lower walls256,258. After welds are formed along the upper and lower walls to enclose the adjacent tubular sections242,244, the upper flange portion270extends upward from the upper wall254and the lower flange portion272extends downward from the lower wall256.

As further shown inFIG.8A, the intermediate portion of the outer sill member216has an upper wall section230that is formed in a stepped shape that integrally interconnects with a generally planar and vertically oriented, outermost wall section232. The outermost wall section232extends down to integrally interconnect with a generally planar lower wall section234that is slightly angled from a horizontal orientation. The stepped shape of the upper wall section230reduces the distance across the hollow interior218between the inner and outer sill members214,216at the upper portion of the inner sill member214.

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.