Patent ID: 7634891

Claim:
A hybrid beam comprising: a metal beam component extending in a longitudinal direction from one end to another end, the metal beam component comprising two web elements extending longitudinally, and upper and lower flange elements extending longitudinally, wherein the upper and lower flange elements extend from one web element to the other web element in a box beam configuration; at least a portion of the web elements and one of the flange elements configured to form a first flange filler enclosure, and at least another portion of the web elements and the other of the flange elements configured to form a second flange filler enclosure; a composite material component comprising a first filler element disposed within the first flange filler enclosure and a second filler element disposed within the second flange filler enclosure, each of the first and second filler elements comprised of a fibrous material embedded in a matrix material; a first pair of opposed extensions extending inwardly from the two web elements to retain the first filler element in the first flange filler enclosure; a second pair of opposed extensions extending inwardly from the two web elements to retain the second filler element in the second flange filler enclosure; and the first and second flange filler enclosures covering at least a portion of an externally facing surface of the composite material component; and a central region of the box beam configuration between the first and second flange filler enclosures free of the composite material component.