Patent Publication Number: US-2023147528-A1

Title: Vehicle rocker assembly

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority under 35 U.S.C § 119(e) to U.S. Provisional Patent Application No. 63/276,282, filed Nov. 5, 2021, the disclosure of this prior application is considered part of this application and is hereby incorporated by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates to sill assemblies and more specifically to tubular inserts for vehicle rocker assemblies for vehicle body structures. 
     BACKGROUND 
     Vehicle frames and body structures are designed to support the vehicle and undergo and absorb certain levels of impact forces, such as to prevent distances of inboard intrusion into the vehicle in accordance with insurance requirements and other regulatory and legal requirements. Side impacts to a vehicle are commonly tested with side pole impact testing, which direct significant side impact forces to the vehicle. Vehicle frames primarily absorb these side impacts at rocker sections that run longitudinally between the front and rear wheels along the lower outboard portions of the vehicle frame. 
     With the incorporation of battery trays in electric and hybrid electric vehicles in the lateral inboard area between opposing rocker sections, it is desirable for the side impact forces to be directed away from the battery tray and towards a vehicle floor cross member. For example, it is generally known to increase stiffness of a vehicle sill assembly such as by adding a tubular insert within the vehicle sill assembly. 
     SUMMARY 
     The present disclosure provides a vehicle rocker assembly. Examples of the vehicle rocker assembly may include a sill inner comprising a sill wall portion, an upper wall portion, a lower wall portion, an upper flange portion, and a lower flange portion. The vehicle rocker assembly may also include a sill outer comprising a sill wall portion, an upper wall portion, a lower wall portion, an upper flange portion, and a lower flange portion. In some examples, the upper flange portion of the sill inner is coupled with the upper flange portion of the sill outer, and the lower flange portion of the sill inner is coupled with the lower flange portion of the sill outer to enclose an elongated hollow interior of the vehicle rocker assembly. The vehicle rocker assembly may also include a tubular insert disposed within the elongated hollow interior. The tubular insert may include an inboard wall disposed adjacent the sill inner, an outboard wall disposed adjacent the sill outer, an upper wall extending between upper ends of the inboard and outboard walls, a lower wall extending between lower ends of the inboard and outboard walls, and a center wall disposed between the upper and lower walls. The center wall may extend between the inboard and outboard walls with a length less than the upper and lower walls. 
     Implementations of the disclosure may include one or more of the following optional features. In some examples, the outboard wall includes a channel that protrudes inboard into the tubular insert. In some examples, the channel comprises a V-shape. 
     Additionally, in some examples the outboard wall includes a first leg and a second leg that protrude inboard from the sill outer to interconnect with the center wall. Moreover, in some examples, upper and lower walls are substantially parallel, and wherein the center wall is angled relative to the upper and lower walls. 
     The details of one or more examples 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. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a side elevation view of a vehicle showing a vehicle rocker assembly including a tubular insert; 
         FIG.  2    is an upper perspective view of a vehicle showing the rocker assembly including a tubular insert and other structural components; 
         FIG.  3    is a cross-sectional view of an example of the vehicle rocker assembly including the tubular insert; 
         FIG.  4    is a cross-sectional view of the example of the tubular insert shown in  FIG.  3   ; 
         FIG.  5    is a cross-sectional view of another example of the tubular insert; 
         FIG.  6    is a cross-sectional view of another example of the tubular insert; 
         FIG.  7    is a cross-sectional view of another example of the tubular insert; 
         FIG.  8    is a cross-sectional view of another example of the tubular insert; 
         FIG.  9    is a cross-sectional view of another example of the tubular insert; and 
         FIG.  10    is a cross-sectional view of another example of the tubular insert. 
     
    
    
     Like reference numerals indicate like parts throughout the drawings. 
     DETAILED DESCRIPTION 
     Referring now to the drawings and the illustrative embodiments depicted therein, a vehicle rocker assembly  10  is provided for a vehicle  100 , such as for a body structure or frame  101 , such as shown in  FIGS.  1  and  2   . The vehicle frame  102  and associated components may have various designs and configurations, such as for different styles and types of vehicles. As shown for example  FIGS.  1  and  2   , the vehicle frame  102  may include a rocker assembly  10 , a B-pillar, a floor cross-member, and a hinge pillar, among various other vehicle frame components. Also, as shown in  FIG.  1   , the vehicle may be partially operated by a propulsion system that uses a battery, such as battery modules that are supported in a battery tray  104  generally located between the axles and near the floor of the vehicle to distribute the battery weight and establish a low center of gravity for the vehicle. Accordingly, the vehicle rocker assembly and associated insert may also or alternatively be implemented as a battery tray frame component. 
     The vehicle rocker assembly  10  may be used as a structural frame component or a battery tray component, either of which are designed to undergo various impact forces and designed to support and sustain different loading conditions. While designing the vehicle to meet the required impact and loading requirements, the outer dimensions of the vehicle component may be reduced and the overall weight of the associated vehicle component may be reduced by providing a tubular reinforcement insert at the desired section of an interior of the vehicle component. In some examples, the tubular insert may span a partial section or the entire length of the vehicle rocker assembly or battery tray. The rocker assembly  10  shown in  FIG.  1    is disposed alongside an outer section of a battery tray  104  that is attached to the vehicle rocker assembly  10 . 
     The vehicle rocker assembly  10  includes a sill panel or panels, such as a sill inner panel  12  and sill outer panel  14  that attach together around an interior area  16 , where the terms “inner” and “outer” are made in reference to inboard or inward facing and outboard or outward facing directions on the vehicle, such oriented in  FIGS.  1  and  2   . As shown in  FIG.  3   , the example of the vehicle rocker assembly  10  is provided with a reinforcement insert disposed in the interior area  16  to form a multi-tubular rocker structure. 
     When designing the vehicle rocker assembly  10  with a reinforcement or tubular insert disclosed herein, the outer dimensions of the vehicle rocker assembly may be reduced and the overall weight of the vehicle rocker assembly  10  may be reduced while meeting the required impact and loading conditions. The tubular insert may span a partial section of the vehicle rocker assembly or the entire length of the rocker assembly, such as to extend beyond the rocker assembly into and to also reinforce an adjacent component. The tubular insert disclosed herein may comprise the entire vehicle component or may be joined to additional reinforcements or parts of the vehicle component, such as at desired sections of the vehicle component. Further, in some examples the rocker assembly may be embodied as a subassembly or as part of a corresponding vehicle component, such as a structural component or a battery tray component and as such may be designed to undergo various impact forces and to support and sustain different loading conditions. 
     Moreover, the tubular insert disclosed herein may be formed with one or more pieces of sheet material, such as by roll forming a metal sheet, to provide the structure with a relatively high strength (for shear and axial loading) and low weight in comparison to common rocker panels, such as to allow the still panels of the corresponding vehicle component (if provided) to use less material, occupy a smaller packaging space, and have greater flexibility in the outer shape design. The cross-sectional shape of different examples of the vehicle component and tubular insert may include various shapes and thicknesses for the desired application of the vehicle component. 
     Unless specified to the contrary, it is generally understood that additional implementations of the rocker assembly may have an opposite orientation from the examples shown and described, such as where the sill panels identified as an inner panel may be used as the outer panel and the sill panels identified as an outer panel may be used as the inner panel. The cross-sectional shape of the inner and outer panels may vary along the rocker, such as, for example, by flaring outward at the ends. 
     Referring now to the vehicle rocker assembly  10  shown in  FIG.  3   , a first sill panel  12  and a second sill panel  14  are attached together to surround a hollow interior space  16  between the sill panels  12 ,  14 . The vehicle rocker assembly  10  shown in  FIG.  3    is embodied as a vehicle rocker component. Accordingly, the first sill panel  12  may be referred to as a sill inner panel of a rocker component. The first sill panel  12  has an upper flange  18  and a lower flange  20  that extend along respective upper and lower edges of the inner panel. The first sill panel  12  protrudes inboard from the upper and lower flanges  18 ,  20  to form outward facing concave structures. The second sill panel  14 , which may be referred to as a sill outer panel of a rocker component, has a C-shaped cross section with flanges  22 ,  24 , which may similarly be referred to as an upper flange  22  and a lower flange  24 . The upper flanges  18 ,  22  and the lower flanges  20 ,  24  of the inner and outer sill panels  12 ,  14  are attached together, such as via welding, with the concave structures facing each other. The upper and lower flanges  18 ,  20 ,  22 ,  24  of each of the sill panels  12 ,  14  shown in  FIG.  3    extend longitudinally, continuously along the edges of the rocker component; however, it is contemplated that the flanges may be trimmed away in select areas to facilitate frame attachment or to reduce weight. 
     As further shown in  FIG.  3   , the inner and outer sill panels  12 ,  14  are joined together to define a hollow interior space  16  between the sill panels  12 ,  14 . The upper and lower flanges  18 ,  20 ,  22 ,  24  are substantially planar and oriented in a generally vertical configuration, such as to mate in generally continuous contact along the length of the component. The upper and lower flanges  18 ,  20 ,  22 ,  24  may be joined together via welding, and preferably spot welding, although it is conceivable that alternative welding methods or joining means may be used in addition or in the alternative to spot welding in different implementations of a rocker component, such as adhesive or fasteners or the like. 
     The first sill panel  12 , or inner panel of the vehicle rocker assembly  10 , has an inner wall  26  that is substantially planar. The inner wall  26  integrally interconnects with a corner transition to an upper wall  28  and a lower wall  30  at the respective upper and lower ends. The corner transitions are approximately 90 degrees between the inner wall  26  and the upper and lower walls  28 ,  30 . Also, the corner transitions are defined by the longitudinal bends to a sheet material that forms the first sill panel  12 , such as a metal sheet (e.g., an advanced high strength steel sheet or aluminum sheet). Similarly, the upper and lower walls  28 ,  30  each have a corner transition of approximately 90 degrees to the upper flange  18  and the lower flange  20 , respectively. The corner transitions are also defined by longitudinal bends in the sheet material of the first sill panel  12 , such as formed by a roll form process. As also shown in  FIG.  3   , the upper and lower flanges  18 ,  20  are substantially planar and oriented in parallel alignment with the planar extent of the inner wall  26 . The upper and lower walls  28 ,  30  of the first sill panel  12  are also substantially planar and, as shown in  FIG.  3   , slightly angled from each other, although in additional examples they may be are substantially parallel to each other. The corner transitions may also have an angular transition greater or less than shown in  FIG.  3   , such as approximately between 40 and 120 degrees, between 70 and 100 degrees, between 80 and 95 degrees, or between 82 and 92 degrees. 
     As also shown in  FIG.  3   , the second sill panel  14  or outer panel of the vehicle rocker assembly  10  has an outer wall  32  that is substantially planar and integrally interconnects with an upper wall  34  and a lower wall  36  at its respective upper and lower ends. The corner transitions of approximately 80 degrees between the outer wall  32  and the upper and lower walls  34 ,  36  are defined by longitudinal bends to a sheet material that forms the second sill panel  14 . The sheet material may be the same or different from the first sill panel  12  and may include a metal sheet, such as an advanced high strength steel sheet or aluminum sheet. Similarly, the upper wall  34  also has a corner transition to the upper flange  22  and the lower wall  36  has a corner transition to the lower flange  24 , which are each also defined by longitudinal bends in the sheet material of the second sill panel  14 . Again, the corner transitions between the upper and lower walls  34 ,  36  and the upper and lower flanges  22 ,  24  and the outer wall  32  may have an angular transition greater or less than shown in  FIG.  4   , such as approximately between 40 and 120 degrees, between 70 and 100 degrees, between 80 and 95 degrees, or between 82 and 92 degrees. 
     As shown in  FIG.  3   , the upper and lower flanges  22 ,  24  are substantially planar and oriented in parallel alignment with the planar extent of the outer wall  32 . The upper and lower walls  34 ,  36  of the second sill panel  14  are also substantially planar, but are slightly angled from being orthogonal to the outer wall  32  and flanges  22 ,  24 . With the flanges  18 ,  20 ,  22 ,  24  of the panels  12 ,  14  attached together, the walls thereof define a substantially hexagonal cross-sectional shape; however, it is appreciated that additional examples of the tubular insert may have various alternative cross-sectional shapes (e.g., a substantially rectangular shape) and different wall configurations for the corresponding vehicle design (e.g., portions of the inner or outer walls that are not vertically oriented). It is also contemplated that in other examples the outer sill and the inner sill may each include a different configuration including but not limited to the outer sill having an inward or outward protruding stiffening rib portion configured to provide additional stiffness and side impact support. 
     As further shown in  FIGS.  3  and  4   , the vehicle rocker assembly  10  includes a tubular insert  40  disposed within the elongated hollow interior  16 . The tubular insert  40  includes an inboard wall  42  disposed adjacent the sill inner  12 , an outboard wall  44  disposed adjacent the sill outer  14 , an upper wall  46  extending between upper ends of the inboard and outboard walls  42 ,  44 , and a lower wall  48  extending between lower ends of the inboard and outboard walls  42 ,  44 . The tubular insert  40  also includes a center wall  50  disposed between the upper and lower walls  46 ,  48  and extending between the inboard and outboard walls  42 ,  44 . In some examples, the center wall  50  has a length less than a length one or both of the upper wall  46  and the lower wall  48 . The upper wall  46 , the inboard wall  42 , the outboard wall  44 , and the center wall  50  define an upper hollow interior  52  and the lower wall  48 , the inboard wall  42 , the outboard wall  44 , and the center wall  50  define a lower hollow interior  54  creating a multi-hollow tubular structure. 
     Moreover, in the example shown in  FIGS.  3  and  4   , the upper and lower walls  46 ,  48  generally extend horizontally and substantially parallel to one another. However, it is also contemplated that the upper and lower walls  46 ,  48  may extend at a different angle such as an angle between 0-30 degrees or 0-15 degrees. Moreover, in some examples, the upper and lower walls  46 ,  48  may extend at different angles from one another such that the upper and lower walls  46 ,  48  do not extend parallel to one another. Additionally, in some examples, one or more of the upper or lower walls  46 ,  48  may include recessed portions or channels or other structural features. 
     Referring still to the example shown in  FIGS.  3  and  4   , the upper and lower walls  46 ,  48  extend between the inboard and outboard walls  42 ,  44 . In one example, the outboard wall  44  is coupled to the outer wall  32  of the second sill member  14 . In the example shown, the outboard wall  44  includes a first leg  56  extending from the upper wall  46  and a second leg  58  extending from the lower wall  48 . The first leg  56  and the second leg  58  protrude inward to interconnect with the center wall  50 . The coupling between the first leg  56  and the second leg  58  and/or the center wall  50  may be a welded coupling, or the first leg  56 , the second leg  58 , and/or the center wall  50  may be coupled by another method as desired. In the example shown, the first leg  56  is coupled to the center wall  50  which extends from the second leg  58  such that a separate coupling between the second legs  58  and the center wall is not needed. However, it is also contemplated that the first leg  56 , the second leg  58 , and/or the center wall  50  may be integrally formed such that no additional coupling techniques are used, such as in example where the tubular insert is an aluminum extrusion. 
     Moreover, as shown in  FIGS.  3  and  4   , the protruding inward first and second legs  56 ,  58  may define a channel  60  that protrudes inboard into the tubular insert  40 . The channel  60  comprises a V-shape. The channel  60  may have a length that is the same as the length of the first and second legs  56 ,  58  or may only partially extend the length of the first and/or second legs  56 ,  58 . Moreover, the channel may be of another shape such as U-shape or variation thereof. Additionally, in the example shown, the first leg  56  of the outboard wall  44  extends substantially vertically from the upper wall  46  before protruding inward. The angle of protrusion inward may be a sharp approximately 45 degrees as shown in  FIGS.  3  and  4    or may be another angle such as between 25-90 degrees. It is also contemplated that the angle of protrusion may be more curved than sharp, as desired. Additionally, the angle between the upper wall  46  and the first leg  56  of the outboard wall  44  may be another angle than substantially vertical such as between 25-120 degrees or any may form a curve or other shape as desired. Referring still to the example shown in  FIGS.  3  and  4   , the second leg  58  may extend from the lower wall  48  at a curved angle of approximately 45 degrees. However, similar to the first leg  56  as described above, the second leg  58  may extend in a variety of ways from the lower wall  48  including but not limited to substantially vertically, and/or at a sharp of curved angle of between 20-120 degrees. 
     As shown in the example illustrated in  FIGS.  3  and  4   , the inboard wall  42  extends between the upper and lower wall  46 ,  48 . In one example, the inboard wall  42  is coupled to the outer wall  26  of the first sill member  12 . The coupling may be by welding or other known coupling techniques. The inboard wall  42  includes a first leg  62  extending from the upper wall  46  and a second leg  64  extending from the lower wall  48 . The first leg  62  and the second leg  64  protrude inward to interconnect with the center wall  50 . The coupling between the first leg  62  and the second leg  64  and/or the center wall  50  may be a welded coupling, or the first leg  62 , the second leg  64 , and/or the center wall  50  may be coupled by another method as desired. In the example shown, the first and second legs  62 ,  64  are coupled to one another and the center wall  50  extends therefrom such that separate coupling to the center wall  50  is not needed. However, it is also contemplated that the first leg  62 , the second leg  64 , and/or the center wall  50  may be integrally formed such that no additional coupling techniques are used. 
     Furthermore, as shown in  FIGS.  3  and  4   , the protruding inward first and second legs  62 ,  64  may define a channel  66  that protrudes outboard into the tubular insert  40 . In the example shown, the channel  66  comprises a U-shape. The channel  66  may have a length that is the same as the length of the first and second legs  56 ,  62 ,  58 ,  64  or may only partially extend the length of the first and/or second legs  58 ,  64 . Moreover, the channel  66  may be of another shape such as a V-shape. Referring still to the example shown in  FIGS.  3  and  4   , the first leg  62  may extend from the upper wall  46  at a curved angle of approximately 45 degrees. However, the second leg  64  may extend in a variety of ways from the lower wall  48  including but not limited to substantially vertically, and/or at a sharp of curved angle of between 20-120 degrees. Additionally, in the example shown, the second leg  64  of the inboard wall  42  extends substantially vertically from the upper wall  46  before protruding inward. The angle of protrusion inward may be approximately 45 degrees as shown in  FIGS.  3  and  4    or may be another angle such as between 25-90 degrees. Additionally, the angle between the upper wall  46  and the first leg  62  of the inboard wall  42  may be another angle than substantially vertical such as between 25-120 degrees or any may form a curve or other shape as desired. In some examples, the first leg  62  and the second leg  64  are similar shapes and lengths to one another, however, various other shapes have been contemplated and some will be described with respect to various other examples below. 
     Referring still to the example shown in  FIGS.  3  and  4   , the center wall  50  extends between the inboard wall  42  and the outboard wall  44 . The center wall  50  has a length that is shorter than the length of one or more of the upper wall  46  and/or the lower wall  48 . In the example shown in  FIGS.  3  and  4   , the length of the center wall  50  is defined between the connections with the legs at the inboard and outboard walls  42 ,  44  and is less than the length of both the upper wall  46  and the lower wall  48 . Having the center wall  50  with a length less than one or more of the upper wall  46  and/or the lower wall  48 , provides more stabilization to the center wall  50  and also allows the center wall  50  to absorb more energy or resist higher loads prior to failing or buckling. 
     As additionally shown in  FIGS.  3  and  4   , the center wall  50  is substantially parallel with both the upper wall  46  and the lower wall  48 . However, other variations have been contemplated including but not limited to the center wall  50  extending parallel to only one of the upper wall  46  or the lower wall  48  or the center wall  50  having a different angle of extension from both the upper wall  46  and the lower wall  48  such that the center wall  50  is not parallel with either the upper wall  46  or the lower wall  48 . Having the center wall  50  disposed between the upper wall  46  and the lower wall  48  also provides for three load carrying walls in one direction allowing the tubular insert  40  to absorb more energy or resist higher loads before failing or buckling. 
     Referring now to the example shown in  FIG.  5   , the tubular insert  140  is similar to the tubular insert  140  as described above with respect to  FIGS.  3  and  4   , including but not limited to the tubular insert  140  including an inboard wall  142  disposed adjacent the sill inner, an outboard wall  144  disposed adjacent the sill outer, an upper wall  146  extending between upper ends of the inboard and outboard walls  142 ,  144  and a lower wall  148  extending between lower ends of the inboard and outboard walls  142 ,  144 . The tubular insert  140  also includes the center wall  150  disposed between the upper and lower walls  146 ,  148  and extending between the inboard and outboard walls  142 ,  144  with the center wall  150  having a length less than a length of one or more of the upper and/or lower wall  146 ,  148 . However, in the example shown in  FIG.  5   , the first and second legs  156 ,  162 ,  158 ,  164  of the outboard walls  142 ,  144  protruded inward at a smaller angle than what is illustrated in  FIGS.  3  and  4    such that the V-shaped channel is deeper and the center wall  150  is shortened ever further. 
     Referring now to the example shown in  FIG.  6   , the tubular insert  240  is similar to the tubular insert  240  as described above with respect to  FIGS.  3  and  4   , including but not limited to the tubular insert  240  including an inboard wall  242  disposed adjacent the sill inner, an outboard wall  244  disposed adjacent the sill outer, an upper wall  246  extending between upper ends of the inboard and outboard walls  242 ,  244 , and a lower wall  248  extending between lower ends of the inboard and outboard walls  242 ,  244 . The tubular insert  240  also includes the center wall  250  disposed between the upper and lower walls  246 ,  248  and extending between the inboard and outboard walls  242 ,  244  with the center wall  250  having a length less than a length of one or more of the upper and/or lower wall  246 ,  248 . However, in the example shown in  FIG.  6   , each of the first legs  256 ,  262  and second legs  258 ,  264  of the inboard wall  242  and outboard wall  244  extend at a substantially curved angle of approximately 45 degrees from the upper wall  246  and the lower wall  248  and protrude towards one another at the same or similar angle such that the center wall  250  is disposed centrally between the first legs  256 ,  262  and second legs  258 ,  264  of the inboard wall  242  and the outboard wall  244  providing a substantially symmetrical tubular structure. As also shown in the example shown in  FIG.  6   , both the channel formed by the first and second legs  256 ,  262 ,  258 ,  264  of the inboard wall  242  and the first and second legs  256 ,  262 ,  258 ,  264  of the outboard wall  244  may form a V-shaped channel. It is also contemplated that the curved angles may be sharp angles and/or have another angle from the upper wall  246  and lower wall  248  including but not limited to 20-120 degrees. Moreover, it is also contemplated that the first and second legs  256 ,  262 ,  258 ,  264  on one of the inboard side or the outboard side may have a longer length such that the tubular insert  240  is not substantially symmetrical. It is also contemplated that one of the inboard wall  242  or outward wall may extends towards the center wall  250  at a different angle than the other such that the corresponding channels formed are different sizes. 
     Referring now to the example shown in  FIG.  7   , the tubular insert  340  is similar to the tubular insert  340  as described above with respect to  FIGS.  3  and  4   , including but not limited to the tubular insert  340  including an inboard wall  342  disposed adjacent the sill inner, an outboard wall  344  disposed adjacent the sill outer, an upper wall  346  extending between upper ends of the inboard and outboard walls  342 ,  344 , and a lower wall  348  extending between lower ends of the inboard and outboard walls  342 ,  344 . The tubular insert  340  also includes the center wall  350  disposed between the upper and lower walls  346 ,  348  and extending between the inboard and outboard walls  342 ,  344  with the center wall  350  having a length less than a length of one or more of the upper and/or lower wall  346 ,  348 . However, in the example shown in  FIG.  7   , each of the first legs  356 ,  362  and second legs  358 ,  364  of the inboard wall  342  and outboard wall  344  extend at a substantially curved angle of approximately 60 degrees from the upper wall  346  and the lower wall  348  and then protrude towards one another at a more vertical angle while the center wall  350  is disposed centrally between the first legs  356 ,  362  and second legs  358 ,  364  of the inboard wall  342  and the outboard wall  344  providing a substantially symmetrical tubular structure. As also shown in the example shown in  FIG.  7   , the more vertical nature of the first and second legs  356 ,  362 ,  358 ,  364  of the both the inboard wall  342  and the outboard wall  344  form a generally U-shaped channel. It is also contemplated that the curved angles may be sharp angles and/or have another angle from the upper wall  346  and lower wall  348  including but not limited to 20-120 degrees. Moreover, it is also contemplated that the first and second legs  356 ,  362 ,  358 ,  364  on one of the inboard side or the outboard side may have a longer length such that the tubular insert  340  is not substantially symmetrical. It is also contemplated that one of the inboard wall  342  or outboard wall  344  may extends towards the center wall  350  at a different angle than the other such that the corresponding channels formed are different sizes. 
     Referring now to the example shown in  FIG.  8   , the tubular insert  440  is similar to the tubular insert  440  as described above with respect to  FIGS.  3  and  4   , including but not limited to the tubular insert  440  including an inboard wall  442  disposed adjacent the sill inner, an outboard wall  444  disposed adjacent the sill outer, an upper wall  446  extending between upper ends of the inboard and outboard walls  442 ,  444 , and a lower wall  448  extending between lower ends of the inboard and outboard walls  442 ,  444 . The tubular insert  440  also includes the center wall  450  disposed between the upper and lower walls  446 ,  448  and extending between the inboard and outboard walls  442 ,  444  with the center wall  450  having a length less than a length of one or more of the upper and/or lower wall  446 ,  448 . However, in the example shown in  FIG.  8   , the upper and lower walls  446 ,  448  are substantially parallel, while the center wall  450  is angled relative to the upper and lower wall  446 ,  448 . As shown in  FIG.  8   , the first and second legs  456 ,  462 ,  458 ,  464  of the inboard and outboard walls  442 ,  444  extend similar from the upper and lower walls  446 ,  448  as described with respect to the tubular insert  440  in  FIG.  6   , however, the lengths of the first and second legs  456 ,  462 ,  458 ,  464  are adjusted to accommodate the angled center wall  450 . The angle of the center wall  450  is approximately 445 degrees in the example shown in  FIG.  8   , however various other angles have been contemplated including but not limited to angles between 10 and 120 degrees. Additionally, the center wall  450  may be angled in the opposite direction than shown in  FIG.  8   , such that the portion of the center wall  450  disposed closer to the upper wall  446  is on the outboard side instead of the inboard side as shown in  FIG.  8   . 
     Referring now to the example shown in  FIG.  9   , the tubular insert  540  is similar to the tubular insert  540  as described above with respect to  FIGS.  3  and  4   , including but not limited to the tubular insert  540  including an inboard wall  542  disposed adjacent the sill inner, an outboard wall  544  disposed adjacent the sill outer, an upper wall  546  extending between upper ends of the inboard and outboard walls  542 ,  544 , and a lower wall  548  extending between lower ends of the inboard and outboard walls  542 ,  544 . The tubular insert  540  also includes the center wall  550  disposed between the upper and lower walls  546 ,  548  and extending between the inboard and outboard walls  542 ,  544  with the center wall  550  having a length less than a length of one or more of the upper and/or lower wall  546 ,  548 . However, in the example shown in  FIG.  9   , both the first and second legs  556 ,  562 ,  558 ,  564  of both the inboard and outboard walls  542 ,  544  extend substantially vertically at an angle of approximately 90 degrees from the upper and lower wall  546 ,  548 , respectively. The first legs and the second legs  556 ,  562 ,  558 ,  564  of both the inboard and outboard walls  542 ,  544  then protrude inward at an angle of approximately 45 degrees toward the center wall  550 . The vertical section of the first and second legs  556 ,  564 ,  558 ,  564  of the inboard and outboard walls  542 ,  544  have a longer length than described previously above such that the overall height of the tubular insert  540  shown in  FIG.  9    may be greater than the height of the tubular insert in previously described examples. This greater height may allow the upper and lower walls  546 ,  548  to be coupled to the upper and lower walls  528 ,  534 ,  530 ,  536  of the first and second sill members  12 ,  14  instead of the tubular member being coupled to the sill members at the inboard and outboard walls  542 ,  544 , as described above. Additionally, the configuration illustrated in  FIG.  9   , allows an even shorter length center wall than described above while still allowing for three load carrying walls in a single direction. 
     Referring now to the example shown in  FIG.  10   , the tubular insert  640  is similar to the tubular insert  640  as described above with respect to  FIG.  9   , including but not limited to the tubular insert  640  including an inboard wall  642  disposed adjacent the sill inner, an outboard wall  644  disposed adjacent the sill outer, an upper wall  646  extending between upper ends of the inboard and outboard walls  642 ,  644 , and a lower wall  648  extending between lower ends of the inboard and outboard walls  642 ,  644 . The tubular insert  640  also includes the center wall  650  disposed between the upper and lower walls  646 ,  648  and extending between the inboard and outboard walls  642 ,  644  with the center wall  650  having a length less than a length of one or more of the upper and/or lower wall  646 ,  648 . However, in the example shown in  FIG.  10   , the inboard wall  642  extends substantially vertically between the upper wall  646  and the lower wall such  648  that no channel is formed on the inboard side. 
     The inner and outer sill panels  12 ,  14  and tubular insert  40  may be roll-formed from an advanced high-strength steel with a tensile strength above 1,000 MPA, such as approximately 1,500 MPa. The metal sheet used to roll form the center wall  50  may be approximately 1.2 mm in thickness, such as between 1.0 mm and 1.6 mm. Also, the steel sheet used for the tubular insert  40  and panels of the vehicle component may be galvanized, so as to have a zinc coating that protects against corrosion. In some examples, however, the steel sheet of the tubular insert may not be galvanized, and in other examples the steel sheets that form the vehicle component may not be galvanized. In further examples, the metal sheet that forms the tubular insert is an aluminum sheet. The length of the inner sill panel  12  is substantially equal to a length of the outer sill panel  14 . In additional implementations, the length of the inner sill panel  12  may be shorter than the length of the hollow interior space of the corresponding component, such as between 40% and 100%, between 30% and 90%, or between 30% and 60% of the length of the tubular insert. The sill inner  12  and sill outer  14  may be coupled by welding, using fasteners, adhesive, or another coupling method. The coupling of the tubular insert  40  and one of the sill inner  12  and the sill outer  14  may provide additional strength to the vehicle rocker assembly. 
     Although the tubular insert  40  may have a structure that provides sufficient stiffness and strength, it is contemplated that the vehicle component may include one or more bulkhead members that are disposed generally orthogonally relative to the longitudinal extent of the rocker component. For example, when the outer rocker panel is desired to be further stiffened, such as for protecting battery modules disposed in a tray between rocker assembles, a series of bulkhead members may be disposed at spaced intervals along the hollow interior between an outer wall section of the tubular insert and an outer panel of a rocker component. The bulkhead members may connect to the outer panel and/or tubular insert with a mechanical fastener, welding, adhesive, or any combination thereof. Moreover, it is contemplated that the inner and outer sill panels may include wall stiffeners that may be attached at select locations of the inner and outer panels. For example, the wall stiffeners may be attached at and reinforce the rounded corners of the metal sheets that form the inner and outer panels. It is contemplated that additional or alternative attachment locations may be used in other examples. 
     It is also contemplated that the internal reinforcements of the disclosed vehicle rocker assembly may be incorporated in other types of structural beams, such as in frames and structures of automotive and marine vehicles, buildings, storage tanks, furniture, and the like. With respect to vehicle applications, the vehicle component disclosed herein may be incorporated with various applications of different structural components. The vehicle component may be designed to support and sustain different loading conditions, such as for supporting certain horizontal spans or axial loading conditions. Also, the vehicle component may be designed to undergo various impact forces, such as for the illustrated rocker assemblies, pillar structures, and the like. The cross-sectional geometry, material type selections, and material thickness within the cross-sectional profile of the vehicle component may be configured for such a particular use and the desired loading and performance characteristics, such as the weight, load capacity the beam, force deflection performance, and impact performance of the vehicle component. 
     For purposes of this disclosure, 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 in  FIG.  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.