Patent ID: 8262155

Claim:
A vehicle beam assembly comprising: a main beam having a front side, a top side, a rear side, and a bottom side, wherein at least one side includes a cutout; a main beam support comprising a first end that includes a planar surface, a middle portion, a second end, a first side surface, a top surface having a plurality of holes, a second side surface, and a bottom surface; and an overmolded joint comprising at least two gussets, at least two reinforcement ribs, a load bearing wall, at least one supporting rib, at least one lateral rib, at least one spanning rib, and at least one bottom rib, wherein the first end and the planar surface of the main beam support contact the main beam, wherein the main beam and the main beam support are connected by the overmolded joint in such a manner that the load bearing wall is disposed in at least a portion of the cutout of the main beam, and wherein the at least two gussets of the overmolded joint include a first gusset extending from the first side surface of the main beam support to the main beam and a second gusset extending from the second side surface of the main beam support to the main beam, and wherein the at least two reinforcement ribs include a first reinforcement rib that extends around the main beam support and through a first hole of the main beam support and connects to the load bearing wall, and a second reinforcement rib that extends around the main beam support and through a second hole of the main beam support.