PATENT DOCUMENT

Publication Number: US-10308290-B1
Application Number: US-201715709872-A
Country: US
Kind Code: B1

Title: Vehicle floor and subassemblies thereof

Abstract:
A floor assembly for a passenger vehicle includes a lower floor assembly and an upper floor subassembly coupled to and positioned above the lower floor assembly. The lower floor assembly includes one or more compartments for containing one or more batteries. The upper floor subassembly is a sandwich structure composite.

Claims:
What is claimed is: 
     
       1. A floor assembly for a passenger vehicle comprising:
 a lower plate; 
 an upper plate; 
 a first outboard structure and a second outboard structure positioned vertically between and adhered to the lower plate and the upper plate; and 
 a core positioned laterally between the first outboard structure and the second outboard structure, and positioned vertically between and adhered to the lower plate and the upper plate. 
 
     
     
       2. The floor assembly according to  claim 1 , wherein the first outboard structure and the second outboard structure are extrusions. 
     
     
       3. The floor assembly according to  claim 1 , wherein the first outboard structure and the second outboard structure have a thickness and a width, the width is greater than the thickness, and the first outboard structure and the second outboard structure are metal members. 
     
     
       4. The floor assembly according to  claim 1 , wherein the lower plate and the upper plate each have a thickness that lessens moving in an inboard direction. 
     
     
       5. The floor assembly according to  claim 4 , wherein the lower plate and the upper plate each are selected from the group consisting of a unitary component, a plurality of plates of varying thicknesses that are edge welded together, and a plurality of plates of varying widths that are stacked on and adhered to each other. 
     
     
       6. The floor assembly according to  claim 4 , wherein the core has a thickness that increases moving in the inboard direction. 
     
     
       7. The floor assembly according to  claim 1 , wherein the core is less dense than the first outboard structure and the second outboard structure. 
     
     
       8. The floor assembly according to  claim 7 , wherein the core comprises multiple components that are coupled to each other. 
     
     
       9. The floor assembly according to  claim 8 , wherein the multiple components of the core are of different materials. 
     
     
       10. The floor assembly according to  claim 1 , wherein the first outboard structure and the second outboard structure have a thickness and a width, the width is greater than the thickness, and the first outboard structure and the second outboard structure are metal extrusions;
 wherein the lower plate and the upper plate each have a thickness that lessens moving in an inboard direction; 
 wherein the core is less dense than the first outboard structure and the second outboard structure, and the core has a thickness that increases moving in the inboard direction. 
 
     
     
       11. The floor assembly according to  claim 1 , further comprising:
 a lower floor assembly; 
 wherein the lower plate, the upper plate, the first outboard structure, the second outboard structure, and the core form an upper floor assembly coupled to and positioned above the lower floor assembly;
 and 
 
 wherein the lower floor assembly includes one or more compartments for containing one or more batteries. 
 
     
     
       12. The floor assembly according to  claim 11 , wherein the first outboard structure and the second outboard structure are positioned at outboard locations opposite each other and are each substantially continuously coupled to both the lower plate and the upper plate, and the upper floor assembly is a sandwich structure composite. 
     
     
       13. The floor assembly according to  claim 12 , wherein the first outboard structure and the second outboard structure have a thickness and a width, the width is greater than the thickness, and the first outboard structure and the second outboard structure are aluminum extrusions that each have multiple cavities extending in a fore-aft direction. 
     
     
       14. The floor assembly according to  claim 13 , wherein the lower plate and the upper plate each have a thickness that lessens moving in an inboard direction. 
     
     
       15. The floor assembly according to  claim 13 , wherein the core has a thickness that increases moving inboard. 
     
     
       16. The floor assembly according to  claim 11 , wherein the upper floor assembly is coupled to the lower floor assembly to enclose one or more batteries therein. 
     
     
       17. The floor assembly according to  claim 16 , wherein the upper floor assembly is coupled to the lower floor assembly with elongated fasteners extending vertically through each of the upper floor assembly and the lower floor assembly. 
     
     
       18. The floor assembly according to  claim 11 , wherein the upper floor assembly has a substantially constant thickness.

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This application claims priority to and the benefit of U.S. Provisional Patent Application No. 62/397,005, filed Sep. 20, 2016, and U.S. Provisional Patent Application No. 62/397,056, filed Sep. 20, 2016, the entire disclosures of which are hereby incorporated by reference. 
    
    
     TECHNICAL FIELD 
     The present disclosure pertains to vehicles and, in particular, floor structures for passenger vehicles. 
     BACKGROUND 
     Passenger vehicles for roadways, such as cars, trucks, or other automobiles, include floor structures. It would be advantageous to provide such a floor structure that distributes forces from outboard impacts and/or minimizes a height thereof to maximize space for other uses (e.g., battery storage). 
     SUMMARY 
     In one aspect, a floor assembly for a passenger vehicle includes a lower floor assembly and an upper floor subassembly coupled to and positioned above the lower floor assembly. The lower floor assembly includes one or more compartments for containing one or more batteries. The upper floor subassembly is a sandwich structure composite. 
     In another aspect, a floor assembly for a passenger vehicle includes a lower plate, an upper plate, first and second outboard structures, and a core. The first and second outboard structures are positioned vertically between and coupled to the lower plate and the upper plate. The core is positioned laterally between the first and second outboard structures, and is positioned vertically between and affixed to the lower plate and the upper plate. 
     In a still further aspect, a method is provided for manufacturing a floor assembly of a passenger vehicle. The method includes providing a bottom plate, a top plate, two outboard extrusions, and a core. In another operation, a first adhesive is applied to one of a bottom surface of the core or an upper surface of the bottom plate, and the core is subsequently positioned on the bottom plate. In another operation, a second adhesive is applied to the upper surface on each side of the core, and the outboard structures are subsequently positioned on the second adhesive on each side of the core. In another operation, a third adhesive is applied to an upper surface of the core, a fourth adhesive is applied to upper surfaces of the outboard structures, and subsequently the upper plate is positioned on the third adhesive and on the fourth adhesive. In a further operation, the bottom plate, the top plate, the two outboard extrusions, and the core are pressed together at a temperature for a duration to cure the first adhesive, the second adhesive, the third adhesive, and the fourth adhesive. 
     In another aspect, a sill assembly for a vehicle includes an energy-absorbing region and a force-spreading region. The energy-absorbing region is elongated in a fore-aft direction and includes an inboard subregion and an outboard subregion. The outboard subregion is arranged outboard of and proximate to the inboard subregion. The force-spreading region is elongated in the fore-aft direction and is arranged outboard of and proximate to the energy-absorbing region and spreads force from outboard loading to the energy-absorbing region. Along the fore-aft direction, the force-spreading region has greater inboard compressive strength than the outboard subregion, and the outboard subregion has greater compressive strength than the inboard subregion. A floor assembly for a vehicle includes an inner floor assembly and two of the sill assemblies. The inner floor assembly includes an upper floor subassembly, a lower floor subassembly, and an intermediate floor subassembly positioned vertically between the upper floor subassembly and the lower floor subassembly and also containing one or more batteries. The two sill assemblies are positioned on opposite outboard sides of the inner floor assembly. Each sill assembly is configured to distribute substantially greater amounts of force from outboard loading to the upper floor subassembly and the lower floor subassembly than to the intermediate floor subassembly. 
     In yet another aspect, a floor assembly includes an inner floor assembly and two sill assemblies. The inner floor assembly includes an upper floor subassembly, a lower floor subassembly, and an intermediate floor subassembly positioned vertically between the upper floor subassembly and the lower floor subassembly and also containing one or more batteries. The two sill assemblies are positioned on opposite outboard sides of the inner floor assembly. Each sill assembly is configured to distribute substantially greater amounts of force from outboard loading to the upper floor subassembly and the lower floor subassembly than to the intermediate floor subassembly. 
     In a still further aspect, a sill assembly includes an upper inboard load structure, a lower inboard load structure, and an outboard load structure. The lower inboard load structure is arranged below the upper inboard load structure. The outboard load structure vertically overlaps the upper inboard load structure and the lower inboard load structure, and is positioned proximate thereto to transfer force thereto from outboard loading. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a top schematic view of a vehicle according to an embodiment. 
         FIG. 2  is an upper, left, front perspective view of a floor structure of the vehicle of  FIG. 1   
         FIG. 3  is a top plan view of the floor structure of  FIG. 2 . 
         FIG. 4  is a cross-sectional view of the floor structure taken along line  4 - 4  in  FIG. 3 . 
         FIG. 5  is a cross-sectional view of the floor structure taken along line  5 - 5  in  FIG. 3 . 
         FIG. 6  is a detail cross-sectional view of the floor structure taken along line  6  in  FIG. 4 . 
         FIG. 7  is an exploded view of a floor assembly of the floor structure of  FIG. 2 . 
         FIG. 8  is an assembled view of the floor assembly shown in  FIG. 7 . 
         FIG. 9  is a flow chart for a method of assembling the floor structure shown in  FIGS. 2, 7, and 8 . 
         FIG. 10  is a partial cross-sectional view of an upper floor subassembly in a first state during a second method of assembly in which an adhesive layer is applied to a core. 
         FIG. 11  is another partial cross-sectional view of the upper floor subassembly shown in  FIG. 10  in a second state during the second method of assembly. 
         FIG. 12  is another partial cross-sectional view of the upper floor subassembly shown in  FIG. 10  in a third state during the second method of assembly. 
         FIG. 13  is a cross-sectional view of the upper floor subassembly shown in  FIG. 10  in a fourth state during the second method of assembly. 
         FIG. 14  is a cross-sectional view of the upper floor subassembly shown in  FIG. 10  in an assembled state resulting from the second method of assembly. 
         FIG. 15  is a partial top view of the upper floor subassembly as shown in  FIG. 10  with the adhesive layer shown partially applied to the core. 
         FIG. 16  is a side view of the partial upper floor subassemblies shown in  FIGS. 10 and 15  with the adhesive layer having been applied and being applied to the core. 
         FIG. 17  is a partial cross-sectional view of the upper floor subassemblies shown in  FIG. 15  in which an outboard structure has dimensional variance. 
         FIG. 18  is a flow chart for the second method of assembling the floor structure shown in  FIGS. 2 and 15 . 
         FIG. 19  is a cross-sectional view of another outboard structure shown in a first state. 
         FIG. 20  is a cross-sectional view of the outboard structure of  FIG. 19  shown in a second state. 
         FIG. 21  is a cross-sectional view of the outboard structure shown in  FIG. 20  with adhesive beads applied thereto. 
         FIG. 22  is a partial cross-sectional view of an upper floor subassembly incorporating the outboard structure shown in  FIGS. 20-21 . 
         FIG. 23  is a front view of a machine transforming the outboard structure from the state shown in  FIG. 19  into the state shown in  FIG. 20 . 
         FIG. 24  is a side view of the machine shown in  FIG. 23  transforming the outboard structure from the state shown in  FIG. 19  into the state shown in  FIG. 20 . 
         FIG. 25  is a partial cross-sectional view of an upper floor subassembly according to another embodiment. 
         FIG. 26  is a partial cross-sectional view of a lower plate according to an embodiment. 
         FIG. 27  is a partial cross-sectional view of a lower plate according to an embodiment. 
         FIG. 28  is a partial cross-sectional view of an upper floor subassembly according to another embodiment. 
         FIG. 29  is a partial cross-sectional view of an upper floor subassembly according to another embodiment. 
         FIG. 30  is a partial cross-sectional view of an upper floor subassembly according to another embodiment. 
         FIG. 31  is a partial cross-sectional view of an upper floor subassembly according to another embodiment. 
         FIG. 32  is a partial cross-sectional view of an upper floor subassembly according to another embodiment. 
         FIG. 33  is a partial cross-sectional view of an upper floor subassembly according to another embodiment. 
         FIG. 34  is a partial cross-sectional view of a lower plate according to another embodiment. 
         FIG. 35  is a partial cross-sectional view of an upper floor subassembly according to another embodiment. 
         FIG. 36  is a partial cross-sectional view of an upper floor subassembly according to another embodiment. 
         FIG. 37  is a partial cross-sectional view of an upper floor subassembly according to another embodiment. 
         FIG. 38  is a partial cross-sectional view of an upper floor subassembly according to another embodiment. 
         FIG. 39  is a partial cross-sectional view of an upper floor subassembly according to another embodiment. 
         FIG. 40  is an upper, front, left perspective exploded view of a sill assembly according to an embodiment. 
         FIG. 41  is an upper, front, left perspective assembled view of the sill assembly shown in  FIG. 40 . 
         FIG. 42A  is a detail cross-sectional view of the floor assembly taken along line  42  in  FIG. 4 . 
         FIG. 42B  is the detail view from  FIG. 42A  illustrating force transfer from outboard loading. 
         FIG. 42C  is a simplified cross-sectional view of  FIGS. 42A and 42B  illustrating force transfer. 
         FIG. 42D  is a cross-sectional view similar to  FIG. 42C , which illustrates the floor assembly with an alternative sill assembly. 
         FIG. 43  is a partial side view of the floor assembly shown in  FIG. 40 , which depicts overlapping and intersection relationships of load structures of the sill assembly. 
         FIG. 44  is a partial side view of the floor assembly shown in  FIG. 40 , which depicts overlapping and intersection relationships of load structures of another sill assembly. 
         FIG. 45  is a partial side view of the floor assembly shown in  FIG. 40 , which depicts overlapping and intersection relationships of load structures of another sill assembly. 
         FIG. 46  is an upper, front, left perspective assembled view of a sill assembly according to another embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIG. 1 , a vehicle  100  includes a floor assembly  101  having an inner floor assembly  110  (e.g., inner floor structure) and two sill assemblies  102  (e.g., beam or sill structure) that are each coupled to one of two outboard sides of the inner floor assembly  110 . 
     Referring to  FIGS. 2-5 , the inner floor assembly  110  (e.g., primary or inner floor structure or assembly) generally includes an intermediate floor subassembly  220  (e.g., battery housing, middle or intermediate floor structure or assembly) and an upper floor subassembly  230  (e.g., upper floor panel, structure, or assembly) above the intermediate floor subassembly  220 . The inner floor assembly  110  may additionally include a lower floor subassembly  218  (e.g., lower or protection panel, structure, or assembly) positioned below the intermediate floor subassembly  220 . It should be noted, however, that the upper floor subassembly  230  may be used independent of the intermediate floor subassembly  220 . 
     The inner floor assembly  110  is configured to house or contain batteries  224  (e.g., battery assemblies) therein. When the upper floor subassembly  210  is coupled to the intermediate floor subassembly  220  (e.g., with elongated, vertical fasteners  426 ), the upper floor subassembly  230  is positioned over and/or encloses the batteries  224  in the inner floor assembly  110 . The upper floor subassembly  230  is configured to provide a substantially flat (e.g., planar) upper surface, while minimizing the height of the upper floor subassembly  230  and inner floor assembly  110 , which may provide for a desired interior aesthetic, while maximizing space for storing the batteries  224 . That is, the upper surface of the upper floor subassembly  230  forms the uppermost rigid surface of the inner floor assembly  110  (which may be covered by compliant surface materials, such as carpeting, fabric, or padding). 
     The inner floor assembly  110  is configured to distribute forces from outboard loading at concentrated locations. The upper floor subassembly  230  is configured with stiffened outboard regions that resist or limit bending or deformation about vertical axes, and which distribute forces from the outboard loading across the upper floor subassembly  230 . The sill assemblies  102  are additionally configured to absorb force via deformation and also transfer force to the upper floor subassembly  230  and/or to the lower floor subassembly  218 . This allows for the omission or reconfiguring of cross-car beams (i.e., beams extending in the inboard/outboard direction across vehicles) that are typically positioned at an intermediate fore-aft position of conventional vehicles. Omission and/or reconfiguring of such cross-car beams may increase available space for positioning the batteries  224  under the upper floor subassembly  230  and/or within the inner floor assembly  110 . 
     The inner floor assembly  110  additionally forms a substantially rigid assembly that resists bending moments about horizontal axes (e.g., twisting) from unequal forces being applied at different portions of the inner floor assembly  110  (e.g., as the vehicle  100  corners, passes over bumps, etc.). Resisting bending moments about horizontal axes is facilitated by the upper floor subassembly  230  and the lower floor subassembly  218  being spaced apart by the intermediate floor subassembly  220  and being coupled to each other with fasteners  462  at intermediate locations. Additionally, the sill assemblies  102  are coupled to the upper floor subassembly  230  and the lower floor subassembly  218  at outboard locations to prevent shearing (e.g., lateral sliding or shifting) therebetween, which further resists bending of the inner floor assembly  110  about horizontal axes. 
     The intermediate floor subassembly  220  includes a peripheral structure  221  and a lower panel  222 , which cooperatively form an interior space having one or more compartments  223  into which one or more batteries  224  may be positioned. The batteries  224  have a width that is less than the upper floor subassembly  230 . Inner cross-members  225  may span between outboard sides of the peripheral structure  221  to divide the interior space into more than one compartment  223  (e.g., three of the inner cross-members  225  forming four compartments  223  as shown). The inner cross-members  225  may additionally function to stiffen the inner floor assembly  110  to prevent or limit bending about horizontal axes (as described above) and to prevent buckling in vertical and inboard directions. 
     The lower floor subassembly  218  may be configured as one or more continuous plate members (e.g., a steel or aluminum plate that has been stamped, rolled, extruded, or otherwise formed) or may be another structure (e.g., planar structure), such as a sandwich structure composite (e.g., configured similar to the upper floor subassembly  230 ) or other assembly. The lower floor subassembly  218 , in addition to providing structural rigidity to the inner floor assembly  110  as described above, also provides a protective barrier to the underside of the intermediate floor subassembly  220  and the batteries  224  contained therein. 
     Referring to  FIG. 6 , the upper floor subassembly  230  is a sandwich structure composite assembly that generally includes a lower plate  232  (e.g., lower or bottom sheet, facesheet, skin, member, etc.), an upper plate  234  (e.g., top or upper sheet, facesheet, skin, member, etc.), a core  236 , and two outboard structures  240  (e.g., left and right members, extrusions, or assemblies). The outboard structures  240  are positioned at outboard locations of the upper floor subassembly  230  and function to stiffen the upper floor subassembly  230  along outboard edges thereof between forward and rearward ends thereof (e.g., to substantially continuously stiffen the upper floor subassembly). The upper floor subassembly  230  may additionally include a forward structure  238  and a rearward structure  239  (e.g., members or assemblies). 
     The core  236  and the two outboard structures  240  of the upper floor subassembly  230  are positioned vertically between and affixed to the lower plate  232  and the upper plate  234 . The core  236  is positioned laterally between the two outboard structures  240 . For example, as discussed in further detail below, an upper surface of the lower plate  232  is coupled to (e.g., affixed, bonded, adhered, or substantially continuously coupled) to lower surfaces of each of the core  236  and the two outboard structures  240 , while the lower surface of the upper plate  234  is coupled to upper surfaces of each of the core  236  and the two outboard structures  240 . With the lower plate  232  and the upper plate  234  having their upper and lower surfaces, respectively, coupled (e.g., affixed, bonded, adhered, or substantially continuously coupled) to lower and upper surfaces, respectively, of the core  236  and the two outboard structures  240 , the upper floor subassembly  230  is configured to bend as a unit about horizontal axes. Relative lateral sliding (e.g., shearing) is prevented between the lower plate  232  and the upper plate  234  with each of the core  236  and the two outboard structures  240 . In embodiments that include the forward structure  238  and the rearward structure  239 , the lower plate  232  and the upper plate  234  may similarly be coupled (e.g., affixed, bonded, adhered, or substantially continuously coupled) to upper and lower surfaces, respectively, thereof, for the upper floor subassembly  230  to bend as a unit with relative lateral sliding (e.g., shearing) therebetween being prevented. 
     The two outboard structures  240  of the upper floor subassembly  230 , in cooperation with the lower plate  232  and the upper plate  234 , strengthen outboard regions of the upper floor subassembly  230  generally along an entire, or substantial majority of a, fore-aft length of the upper floor subassembly  230 . Each outboard structure  240  and/or outboard regions of the lower plate  232  and the upper plate  234  absorb an outboard impact or load along the length of the upper floor subassembly  230  and distribute the resultant force inboard across the upper floor subassembly  230  (e.g., to inboard portions of the lower plate  232  and the upper plate  234 ) and to other structures of the vehicle  100  (e.g., the intermediate floor subassembly  220 ). The outboard structures  240  in combination with the lower plate  232  and the upper plate  234 , thus, cooperatively resist inboard deflection and/or deformation from the outboard impact, for example, about a vertical axis. The core  236  is made of or otherwise provides a lower cost, lighter weight, and/or weaker material than the outboard structures  240  in inboard regions of the upper floor subassembly  230 . The core  236  prevents vertical deflection or compression between the lower plate  232  and the upper plate  234  and also prevents translational sliding (e.g., shearing) therebetween as mentioned previously. The forward structure  238  and the rearward structure  239  are also configured to transfer the force of an outboard impact across the upper floor subassembly  230 , including forces from concentrated outboard impacts proximate forward and rearward ends of the upper floor subassembly  230 . 
     Referring to  FIGS. 3-6 , each outboard structure  240  of the upper floor subassembly  230  is a generally rigid, elongated member that extends in a fore-aft direction of the vehicle  100 . Each outboard structure  240  may, for example, be a unitary, extruded aluminum (e.g., 2024, 6062, or 7075 aluminum, or other suitable material) component that may also be machined. That is, each outboard structure  240  may be a metal extrusion or metal member, such as an aluminum extrusion. According to other embodiments, the outboard structures  240  may be made from multiple components that are coupled together (e.g., multiple extrusions stir welded together), be made from other materials, and/or be made from other manufacturing methods. While the outboard structures  240  are depicted as having a constant wall thickness (e.g., approximately 4 mm, 3 mm, or 2 mm), the outboard structures  240  may instead have a varying wall thickness (e.g., narrowing moving inboard in a stepped or tapering fashion, such as from approximately 4 mm to 2 mm). 
     Each outboard structure  240  of the upper floor subassembly  230  includes an inboard edge  346  (shown in phantom lines in  FIG. 3 ), an outboard edge  348 , a forward edge  350 , and a rearward edge  352  (see, e.g.,  FIG. 3 ), along with a lower surface  642  and an upper surface  644  (see, e.g.,  FIG. 6 ). The outboard structure  240  additionally includes a plurality of webs  654  that extend vertically to form chambers or cavities  656  (e.g., multiple chambers) between the lower surface  642  and the upper surface  644 , which extend in the fore-aft direction (i.e., the direction of extruding). 
     A width of the outboard structure  240 , as measured between the inboard edge  346  and the outboard edge  348 , is greater than a height of the outboard member  248 , as measured between the lower surface  642  and the upper surface  644 , over a majority of the fore-aft length of the outboard structure  240  (i.e., between the forward edge  350  and the rearward edge  352 ). For example, the width of the outboard structure  240  is approximately twice its thickness or more (e.g., between approximately two and fifteen, such as between five and ten, times the thickness). The thickness of the outboard structure  240  may be substantially constant across its width. For example, the thickness of the outboard structure  240  may be between approximately 15 and 33 mm (e.g., approximately 22 mm) and have a width of between approximately 200 and 300 mm (e.g., approximately 240 mm). According to other embodiments, the outboard structure may have a width that is between approximately one and three times its thickness, such as having a width of between approximately 40 mm and 80 mm (e.g., 50 mm) and a thickness of between approximately 15 and 33 mm (e.g., approximately 22 mm). According to still further embodiments, the outboard structure  240  may have a variable thickness that lessens in a stepped or tapered manner moving in an inboard direction. Variations of the outboard structure  240  are discussed in further detail below. 
     The fore aft-length of the outboard structure  240  is greater than its width. In one example, the length of the outboard structure  240  is approximately twice its maximum width or more (e.g., between approximately two and ten times the width). For example, the outboard structure  240  may have a length of between approximately 1000 mm and 2000 mm (e.g., approximately 1700 mm). The width may be between 200 mm and 300 mm. In another example, the length of the outboard structure is between approximately ten and twenty-five times its width, such as having a length of between approximately 1000 mm and 2000 mm and a width of between approximately 40 mm and 80 mm (e.g., 50 mm). According to other embodiments, the dimensions (i.e., thickness, width, length, and ratios thereof) may be different (e.g., smaller, larger, variable, etc.) as may be appropriate for different applications. 
     The inboard edge  346  of the outboard structure  240  is substantially vertical and extends substantially straight in a fore-aft direction. The inboard edge  346  is positioned proximate an outboard edge  336   a  of the core  236 . The inboard edge  346  may additionally abut and/or be coupled to the outboard edge  336   a  of the core  236 , or may be spaced apart therefrom at a constant or varying distance in an inboard-outboard direction. The inboard edge  346  may be formed during an extruding process of the outboard structure  240  and/or be machined. According to other embodiments, the inboard edge  346  may extend vertically at a non-vertical and/or varying angle, extending at a different angle or varying angles relative to the fore-aft direction. 
     The outboard edge  348  of the outboard structure  240  may be straight in the fore-aft direction as shown, or may follow a curved or convoluted profile corresponding to the sill assembly  102  and a desired outer aesthetic of the vehicle. The outboard edge  348  may be formed during extruding of the outboard structure  240 , or may be machined to form a curved or convoluted profile thereof. In regions of a curved profile, the edges of the lower surface  642  and the upper surface  644  may be disconnected with no web or other portion of the outboard structure  240  extending vertically therebetween. 
     The webs  654  of the outboard structure  240  are substantially vertical and extend substantially straight in the fore-aft direction and in parallel with the inboard edge  346 . While the webs  654  are shown as defining four cavities  656  (e.g., with two external webs  654  forming the inboard edge  346  and the outboard edge  348 , and three internal webs  654 ) in  FIG. 6 , the outboard structure  240  may include any suitable number of webs  654  (e.g., three of the webs  654  to form two of the cavities  656 , and two, four, five, or more of the webs  654  to form other numbers of the cavities  656 ). Further, while the webs  654  are shown as being equally spaced so as to define the cavities  656  with generally equal cross-sectional sizes, the webs  654  may be spaced differently to provide the cavities  656  with different cross-sectional sizes. Still further, while the webs  654  are depicted as being substantially vertical, they may extend at different angles relative to vertical and/or be connected to each other (e.g., forming a corrugated pattern). 
     The core  236  of the upper floor subassembly  230 , as referenced above, is lighter weight (e.g., lower density), less expensive, and/or weaker material than that of the outboard structures  240 , the lower plate  232 , and/or the upper plate  234 . In one example, the core  236  is an aluminum honeycomb sheet or panel having cells (e.g., voids) whose axes extend substantially vertically between the lower plate  232  and the upper plate  234  (see also  FIG. 15 ). According to other embodiments, the core  236  may be another material, such as a honeycomb sheet or panel formed from another material (e.g., another metal, a polymer, etc.), a metal extrusion (e.g., having thinner upper and lower surfaces and/or webs than the outboard structure  240 ), a polymer foam (e.g., rigid foam panel, injected curable foam), a metal foam (e.g., aluminum foam), wood (e.g., balsa wood), an egg crate-type structure (e.g., stamped or 3-dimensional profile), a corrugated structure (e.g., 2-dimensional profile), or other suitable structure or material. The core  236  may also comprise multiple sheets, plates, or members that are positioned laterally adjacent, stacked vertically, and/or coupled to each other. Variations of the core  236  are discussed in further detail below. 
     The core  236  has two outboard edges  336   a , a forward edge  336   b , a rearward edge  336   c , a lower surface  636   d , and an upper surface  636   e . The outboard edges  336   a  extend substantially straight and parallel with each other in the fore-aft direction, or with another profile, to correspond with the inboard edges  346  of the outboard structures  340 . For example, the core  236  may have a width of between approximately 500 and 800 mm (e.g., approximately 650 mm). The forward edge  336   b  and the rearward edge  336   c  extend substantially straight and parallel with each other in the inboard-outboard direction, or with another profile, to correspond with a rearward edge  238   a  of the forward structure  238  and a forward edge  339   a  of the rearward structure  239 , respectively. 
     In embodiments in which the core  236  comprises a honeycomb structure, the outboard edges  336   a , the forward edge  336   d , and the rearward edge  336   c  are formed cooperatively by partial (e.g., cut) vertical walls that define the cells  1536   g  partially formed at outer ends of the honeycomb structure, as opposed to having a continuous edge or peripheral surface (see  FIG. 15 ). Furthermore, the lower surface  636   d  and the upper surface  636   e  are formed cooperatively by the edges  1536   f  at upper and lower ends, respectively, of the vertical walls that define the cells  1536   g  of the honeycomb structure, as opposed to having a continuous surface. 
     The core  236  is coplanar (i.e., having a common horizontal plane extending therethrough) with the outboard structures  240  and has a thickness that is measured in a substantially vertical direction between the lower surface  636   d  and the upper surface  636   e . The thickness of the core  236  has a thickness that is constant across its width and that is the same as the thickness of the outboard structure  240  adjacent thereto. This allows for the lower plate  232  and the upper plate  234  to have a substantially constant thickness across their widths and lengths, such that the upper floor subassembly  230  has a substantially constant thickness across its width and length, and/or to have substantially planar upper and lower surfaces. For example, the core  236  may have a thickness of between approximately 15 and 30 mm (e.g., approximately 22 mm). According to other embodiments, as discussed in further detail below, the core  236  may have a thickness that increases in a tapering or stepped fashion moving inboard and/or laterally toward a center of the upper floor subassembly  230 . 
     The forward structure  238  and the rearward structure  239  of the upper floor subassembly  230  are each a generally rigid, elongated member that extends in the inboard-outboard direction of the vehicle  100 . The forward structure  238  and the rearward structure  239  may, for example, each be a unitary, extruded aluminum component that may also be machined. According to other embodiments, the forward structure  238  and the rearward structure  239  may be made from multiple components that are coupled together, be made from other materials, and/or be made from other manufacturing methods. 
     The forward structure  238  and the rearward structure  239  are coplanar with the outboard structures  240  and the core  236 . The forward structure  238  is positioned forward of the core  236  with its rearward edge  338   a  positioned proximate the forward edge  336   d  of the core  236 , while the rearward structure  239  is positioned rearward of the core  236  with its forward edge  339   a  positioned proximate the rearward edge  336   c  of the core  236 . The rearward edge  338   a  of the forward structure  238  and the forward edge  339   a  of the rearward structure  239  may abut and/or be coupled to the forward edge  336   d  and the rearward edge  336   c , respectively, of the core  236  (e.g., using an expanding splice adhesive), or may be spaced apart therefrom a constant or varying distance in the fore-aft direction. 
     The forward structure  238  and/or the rearward structure  239  may extend between and to the outboard edges  348  of the outboard structures  240 , as is shown for the forward structure  238  in  FIG. 3 , or may extend between and to the inboard edges  346  of the outboard structures  240 , as is shown for the rearward structure  239  in  FIG. 3 . As shown, the outboard structures  240  extend a substantial majority of the fore-aft length of the upper floor subassembly  230  by extending by extending to the forward structure  238 . 
     The forward structure  238  and the rearward structure  239  have a thickness between their lower and upper surfaces (not labeled), which may be the same as the thickness of the outboard structure  240  and/or the core  236  in adjacent regions. This allows for the lower plate  232  and the upper plate  234  to have a substantially constant thickness across their widths, resulting in the upper floor subassembly  230  having a substantially constant thickness across its width and length, and/or have substantially planar upper and lower surfaces. Alternatively, the thickness of the outboard structures  240  may be less than that of the core  236 , which allows for dimensional variation (e.g., warping, twisting, etc.) of the outboard structures  240 , while still maintaining a constant thickness for the upper floor subassembly  230 . 
     The lower plate  232  and the upper plate  234  of the upper floor subassembly  230  are each a generally rigid, planar member that spans substantially the entire fore-aft and inboard-outboard directions of the upper floor subassembly  230 . Each of the lower plate  232  and the upper plate  234  may, for example, be a unitary aluminum sheet of constant thickness (e.g., 2024, 6062, or 7075 aluminum, other aluminum material, or other suitable material). In other embodiments, the lower plate  232  and the upper plate  234  may be made of or include other materials, such as composite materials. For example, the lower plate  232  and/or the upper plate  234  may be made of or include carbon fiber, such as loose or woven carbons fibers set in a polymer (e.g., cured resin). According to other embodiments, as discussed in further detail below, the lower plate  232  and the upper plate  234  may be made from multiple members assembled together, be made from different materials, and/or have varying thicknesses (e.g., thinning in a tapering or stepped fashion moving inboard). 
     As referenced above, the core  236 , the forward structure  238 , the rearward structure  239 , and the outboard structures  240  are arranged vertically between the lower plate  232  (i.e., above the lower plate  232 ) and the upper plate  234  (i.e., below the upper plate  234 ). The lower plate  232  and the upper plate  234  have substantially the same peripheral shape, which has a width extending between the outboard edges  332   a ,  334   a , respectively, thereof, and a length extending between the forward edges  332   b ,  334   b  and the rearward edges  332   c ,  334   c , respectively, thereof. 
     The outboard edges  332   a ,  334   a  of the lower plate  232  and the upper plate  234 , respectively, follow the outboard edges of  348  of the outboard structures  240 . In embodiments in which the outboard edges  348  of the outboard structures  240  are straight and parallel, the outboard edges  332   a ,  334   a  on left and right sides of the lower plate  232  and the upper plate  234  are also straight and parallel with each other, resulting in the lower plate  232  and the upper plate  234  having constant widths along a majority of their fore-aft lengths. In embodiments in which the outboard edges  348  of the outboard structures  240  are not parallel or follow a curved or convoluted profile, the lower plate  232  and the upper plate  234  have varying widths along their fore-aft lengths. 
     Similarly, the forward edges  332   b ,  334   b  of the lower plate  232  and the upper plate  234  follow a forward edge  338   b  of the forward structure  238 , and the rearward edges  332   c ,  334   c  of the lower plate  232  and the upper plate  234  follow a rearward edge  339   c  of the rearward structure  239 . In embodiments in which the forward edge  338   b  of the forward structure  238  and the rearward edge  339   c  of the rearward structure  239  are straight and parallel, the forward edges  332   b ,  334   b  and the rearward edges  332   c ,  334   c  of the lower plate  232  and the upper plate  234  are also straight and parallel with each other, resulting in the lower plate  232  and the upper plate  234  having constant lengths along a majority of their widths. In embodiments in which the forward edge  338   b  of the forward structure  238  and/or the rearward edge  339   c  of the rearward structure  239  are not parallel or follow a curved or convoluted profile, the lower plate  232  and the upper plate  234  have varying lengths across their widths. 
     The lower plate  232  and the upper plate  234  additionally have a constant thickness that, in conjunction with the thicknesses of the core  236 , the forward structure  238 , the rearward structure  239 , and the outboard structures  240 , results in the upper floor subassembly  230  having a constant thickness. For example, the lower plate  232  and/or the upper plate  234  may have a thickness of between approximately 1 mm and 4 mm (e.g., approximately 1.5 mm). In combination with the outboard structures  240  and the core, the upper floor subassembly  230  may have a thickness of between approximately 17 mm and 38 mm (e.g., approximately 25 mm). Alternatively, the lower plate  232 , the upper plate  234 , the core  236 , the forward structure  238 , the rearward structure  239 , and/or the outboard structures  240  may alternatively vary in a cooperative manner to achieve a constant or variable thickness of the upper floor subassembly  230 . 
     With reference to  FIGS. 7-9 , and as mentioned above, the upper surface of the lower plate  232  is coupled (e.g., affixed, bonded, adhered, or substantially continuously coupled) to the lower surfaces of the core  236 , the forward structure  238 , and the rearward structure  239 , as well as to the lower surfaces  642  of the outboard structures  240 . The lower surface of the upper plate  234  is also coupled (e.g., affixed, bonded, adhered, or substantially continuously coupled) to the upper surfaces of the core  236 , the forward structure  238 , and the rearward structure  239 , as well as to the upper surfaces  644  of the outboard structures  240 . In this manner, the upper floor subassembly  230  is configured as a sandwich structure composite. 
     According to one embodiment, the lower plate  232  and the upper plate  234  are affixed using one or more types of adhesives. For example, as shown in  FIGS. 7-8 , which are disassembled and assembled cross-sectional views taken along line  4 - 4  in  FIG. 3 , a lower adhesive layer  761  (e.g., a lower layer of adhesive), such as a film adhesive (e.g., a heat activated adhesive), affixes (e.g., bonds, adheres, etc.) the lower plate  232  to the core  236  and the outboard structures  240 . An upper adhesive layer  762  (e.g., an upper layer of adhesive), such as another film adhesive, affixes (e.g., bonds, adheres, etc.) the upper plate  234  to the core  236  and the outboard structures  240 . The lower adhesive layer  761  and the upper adhesive layer  762  have widths and lengths equal to those of the lower plate  232  and the upper plate  234 , as well as the combined widths and lengths of the core  236  and the outboard structures  240 , so as to affix (e.g., adhere, bond, couple, etc.) the lower plate  232  and the upper plate  234  over an entirety or substantial majority of their respective interfacing surfaces therebetween (i.e., upper and lower surfaces). 
     A splice adhesive  763  may also be positioned between the core  236  and the outboard structures  240 , which affixes (e.g., bonds, adheres, etc.) the outboard edge  336   a  and the inboard edge  346 , respectively, thereof to each other. The splice adhesive  763  may also expand laterally between the outboard edge  336   a  of the core  236  (e.g., into partial cells of the honeycomb structure) and the inboard edge  346  of the outboard structures  240 , respectively, and vertically between the lower plate  232  and the upper plate  234  to form a bond therebetween. 
     As shown in  FIG. 9 , in conjunction with  FIGS. 7-8 , a method is provided for assembling the upper floor subassembly  230 . In a first operation S 902 , the lower adhesive layer  761  is placed (e.g., laid) on the lower plate  232 . In a second operation S 904 , the core  236 , the outboard structures  240 , and the splice adhesives  763  are aligned with each other and placed on the lower adhesive layer  761 . Additionally, the forward structure  238  and the rearward structure  239 , if included, may also be aligned with the core  236  and the outboard structures  240 . In a third operation S 906 , the upper adhesive layer  762  is laid on upper surfaces of the core  236  and the outboard structures  240 , as well as the forward structure  238  and the rearward structure  239  if present. In a fourth operation S 908 , the upper plate  234  is aligned with and positioned on the upper adhesive layer  762 . In a fifth operation S 910 , the resultant layered arrangement is then held under heat (e.g., 175 degrees Celsius, as may be appropriate for the adhesives) and pressure for a duration (e.g., 60 minutes, as may be appropriate for the adhesives). During the fifth operation S 910 , the lower adhesive layer  761 , the upper adhesive layer  762 , and the splice adhesive  763  cure to form the upper floor subassembly  230  as a sandwich structure composite. The heat and pressure applied during the fifth operation S 910  may, for example, be performed with static presses (e.g., that move an upper and/or lower heated platen vertically), or via a rolling press having upper and lower belts that apply pressure as the upper floor subassembly  230  (or components thereof) are moved by the belts through a heated environment. In a sixth operation S 912 , the upper floor subassembly  230  is then cooled to room temperature. 
     In subsequent operations, the upper floor subassembly  230  is further processed. In a seventh operation S 914 , after the upper floor subassembly  230  is formed, flatness tolerance (e.g., flatness) of the upper floor subassembly  230 , if appropriate, may be subsequently corrected (e.g., using a press, rolling, and/or extruding type processes). In an eighth operation S 916 , the upper floor subassembly  230  is machined. For example, the upper floor subassembly  230  may be machined to achieve a desired outer profile by cutting peripheral edges of its various components (e.g., lower plate  232 , upper plate  234 , outboard structures  240 , etc.) to be coextensive with each other and to form outboard edges  330   a , a forward edge  330   b , and/or a rearward edge  330   c  of the upper floor subassembly  230 . The upper floor subassembly  230  may also be machined to facilitate the coupling of other structures thereto, for example, by machining apertures or other mounting features into and/or through the upper floor subassembly  230 . Such machining may be performed, for example, with a cutting blade, drill bit, CNC router, water jet, laser cutter, or other suitable machining device. Instead, or additionally, the various components of the upper floor subassembly may be machined prior to the first operation S 902 . The eighth operation S 916  occurs prior to or after the correcting of the flatness tolerance of the upper floor subassembly  230 . In a ninth operation S 918 , the upper floor subassembly  230  is then coupled to other structures of the vehicle  100 , such as the intermediate floor subassembly  220  or the sill assembly  102  to form the inner floor assembly  110 , or other body structure. In a tenth operation S 920 , other finished structures and/or vehicle components, such as a vehicle seat, are coupled to the upper floor subassembly  230 . 
     As shown in  FIGS. 10-14 , an upper floor subassembly  1430  is configured substantially similar to the upper floor subassembly  230  but uses other types of adhesives instead of or in addition to the film adhesives discussed above. For example, a lower adhesive layer  1071  couples the lower surface  636   d  of the core  236  to the lower plate  232 , an upper adhesive layer  1172  couples the upper surface  636   e  of the core  236  to the upper plate  234 , and lower adhesive beads  1173  and upper adhesive beads  1274  (lower and upper beads of adhesive) couple the lower surface  642  of the outboard structure  240  to the lower plate  232  and couple the upper surface  344  of the outboard structure  240  to the upper plate  234 . 
     The lower adhesive layer  1071  and/or the upper adhesive layer  1172  may be a film adhesive, or may be a liquid or paste adhesive that is applied to the core  236 . For example, as shown in  FIG. 15 , when the core  236  has a honeycomb structure, or other structure having a discontinuous upper surface, the lower adhesive layer  1071  or the upper adhesive layer  1172  is applied to the edges  1536   f  (e.g., upper and lower edges) of vertical walls that define the cells  1536   g  of the honeycomb structure of the core  236 . By applying the adhesive to the edges  1536   f  of the vertical walls defining the cells  1536   g , the amount of adhesive used may be lessened and the resultant weight of the upper floor subassembly  230  lessened, as compared to using a film or other uninterrupted type of adhesive. The lower adhesive layer  1071  and the upper adhesive layer  1172 , thereby, include adhesive only where the core  236  contacts the lower plate  232  or upper plate  234  and regions immediately therearound. The lower adhesive layer  1071  and the upper adhesive layer  1172  may be considered substantially continuously coupled to the lower plate  232  and the upper plate  234 , respectively, despite the adhesive being interrupted above/below the cells  1536   g  (i.e., between the edges  1536   f  of the vertical walls). 
     With reference to  FIG. 16 , the liquid or paste adhesive may be applied to the core  236 , for example, using a roll coating process in a mass production environment. The cores  236  for the upper floor subassemblies  230  are carried successively by a conveyer  1681 , and an adhesive  1675  (e.g., paste or liquid adhesive) is distributed via one or more rollers  1682  to the then-current upper surface of the core  236  (e.g., the lower surface  636   d , as shown). For example, the roll coating process may be a reverse roll coating process in which the roller  1682  rotates in an opposite direction of travel of the conveyer  1681 , so as to wipe or otherwise apply the adhesive  1675  to the core  236 . 
     The lower adhesive beads  1173  (e.g., first group of beads) couple the upper surface of the lower plate  232  to the lower surface  642  of the outboard structure  640  (see, e.g.,  FIG. 11 ), and the upper adhesive beads  1274  (e.g., second group of beads) couple the upper surface  644  of the outboard structure  240  to a lower surface of the upper plate  234  (see, e.g.,  FIG. 12 ). The lower adhesive beads  1173  and the upper adhesive beads  1274  are of a liquid or paste adhesive. The lower adhesive beads  1173  and the upper adhesive beads  1274  may, for example, extend in the direction of elongation of the outboard structure  240 . The lower adhesive beads  1173  and the upper adhesive beads  1274  are of a liquid or paste adhesive (e.g., heat curable). 
     When the outboard structure  240  is placed on the lower adhesive beads  1173 , the adhesive thereof spreads laterally between the upper surface of the lower plate  232  and the lower surface  642  of the outboard structure  640  (see, e.g.,  FIGS. 12-13 ). When spread, the adhesive of the lower adhesive beads  1173  may merge with (e.g., bleed into) the adhesive of adjacent ones of the lower adhesive beads  1173  to form a coating (e.g., a substantially continuous coating) of adhesive  1473 ′ (see, e.g.,  FIG. 14 ), or may maintain a slight lateral gap between the lower adhesive beads  1173  (see, e.g.,  FIGS. 12-13 ). Similarly, as the upper plate  234  is first placed and subsequently pressed on the upper adhesive beads  1274 , the adhesive of the upper adhesive beads  1274  spreads laterally and may merge with (e.g., bleed into) the adhesive of adjacent ones of the upper adhesive beads  1274  to form a coating (e.g., a substantially continuous coating) of adhesive  1474 ′ (see, e.g.,  FIG. 14 ), or may maintain a slight lateral gap between the upper adhesive beads  1274  (see, e.g.,  FIG. 13 ). Even if a lateral gap exists between the lower adhesive beads  1173  or the upper adhesive beads  1274  in the finished upper floor subassembly  1430 , the lower surface  642  and the upper surface  644  of the outboard structure  240  may still be considered substantially continuously coupled to the lower plate  232  and the upper plate  234 , respectively. 
     Each of the lower adhesive beads  1173  and the upper adhesive beads  1274  are provided in such a volume as to couple the mating surfaces of the outboard structure  240  with the lower plate  232  and the upper plate  234 , while also providing the upper floor subassembly  1430  with a substantially constant thickness. Thus, the volume of the lower adhesive beads  1173  and the upper adhesive beads  1274  and the thickness of the outboard structure  240  are configured cooperatively relative to the thickness of the lower adhesive layer  1071 , the upper adhesive layer  1172 , and the core  236  to achieve a substantially constant thickness throughout the upper floor subassembly  1430 . 
     Furthermore, the lower adhesive beads  1173  and the upper adhesive beads  1274  may be provided with a sufficient size to account for warping (e.g., twisting) or other dimensional variations of the outboard structure  240  caused by an extrusion process thereof, while still coupling (e.g., substantially continuously coupling) the outboard structure  240  to the lower plate  232  and the upper plate  234 . For example, as shown in  FIG. 17 , the outboard structure  240  may warp or twist resulting in a varied thickness moving in the inboard-outboard direction (i.e., transverse to the direction of extruding). Depending on the thickness and slope of the outboard structure  240  at varying inboard-outboard locations, the lower adhesive beads  1173  and the upper adhesive beads  1274  spread laterally (i.e., in the inboard-outboard direction) to varying degrees. To ensure a constant thickness of the upper floor subassembly  1430  despite such possible dimensional variations of the outboard structure  240 , the outboard structure  240  has a nominal thickness (i.e., design thickness) that is less than the thickness of the core  236 , since the core  236  dimensions may be more easily controlled (e.g., by machining, extruding, etc.). The resultant volumes between the outboard structures  240  and the lower plate  232  and the upper plate  234  are filled, wholly or partially, by the adhesive of the lower adhesive beads  1173  and the upper adhesive beads  1274 , respectively. While lateral gaps of varying degree may exist between the lower adhesive beads  1173  that are adjacent to each other or the upper adhesive beads  1274  that are adjacent to each other, the lower surface  642  and the upper surface  644  of the outboard structure  240  may still be considered to be substantially continuously coupled to the lower plate  232  and the upper plate  234 , respectively. 
     With reference to  FIG. 18 , a variation of the method described above and shown in  FIG. 9  is used with paste or liquid adhesives. In a first operation S 1802 , the lower adhesive layer  1071  (e.g., paste, liquid, or film adhesive layer) is applied to the lower surface  636   d  of the core  236 , while facing upward (see  FIG. 10 ). In a second operation S 1804 , the core  236  is turned over, then aligned with and placed on the lower plate  232 . In a third operation S 1806 , the lower adhesive beads  1173  are placed on the lower plate  232  (see  FIG. 11 ). In a fourth operation S 1808 , the upper adhesive layer  1172  is applied to the upper surface  636   e  of the core  236 , which may occur before, after, or simultaneously with the third operation S 1806 . In a fifth operation S 1810 , the splice adhesive  763  is positioned on the lower plate  232 , which may occur before, after, or simultaneously with the third operation S 1806  and/or the fourth operation S 1808 . In a sixth operation S 1812 , the outboard structures  240  are aligned with the lower plate  232  and placed on the lower adhesive beads  1173 , which occurs after the third operation S 1806 , but may occur before, after, or simultaneously with the fourth operation S 1808  and/or the fifth operation S 1810 . In a seventh operation S 1814 , the upper adhesive beads  1274  are applied to the upper surfaces  644  of the outboard structures  240 , which occurs after the sixth operation S 1812 . In an eighth operation S 1816 , the upper plate  234  is aligned with and positioned on the upper adhesive beads  1274  and the upper adhesive layer  1172 . Operations S 910  (i.e., apply heat and pressure for a duration to the layered arrangement to form the upper floor subassembly  1430 ) and S 912  (i.e., cooling the upper floor subassembly  130 ) are then performed, as described previously, along with any appropriate operations of S 914  (i.e., correcting the flatness tolerance of the upper floor subassembly  1430 ), S 916  (i.e., machining the upper floor subassembly  1430 ), S 918  (coupling the upper floor subassembly  1430  to the intermediate floor subassembly  220  or other structures of the vehicle), and/or S 920  (coupling other finished structures to the upper floor subassembly  1430 ). 
     With reference to  FIGS. 19-24 , according to an alternative embodiment, an upper floor subassembly  2230  (shown partially in  FIG. 22 ) is configured substantially similar to the upper floor subassemblies  230  and  1430  described previously, but includes outboard structures  1940  in place of the outboard structures  240 . The outboard structure  1940  is configured substantially similar to the outboard structure  240  but includes a plurality of lower protrusions  1942   a  (e.g., ribs) that extend downward from the lower surface  642  a predetermined height, and a plurality of upper protrusions  1944   a  (e.g., ribs) that extend upward from the upper surface  644  the predetermined height or another height. The lower protrusions  1942   a  and the upper protrusions  1944   a  may, for example, be formed as the outboard structure  1940  is extruded. After extruding, the lower protrusions  1942   a  and the upper protrusions  1944   a  may be machined to account for any dimensional variation (e.g., warping, twisting, etc.) resulting from the extruding process that formed the outboard structure  240 . As shown in  FIG. 20 , after machining, lower edges  2042   b  of the lower protrusions  1942   a  define a lower plane along the length and width of the outboard structure  240 , while upper edges  2044   b  of the upper protrusions  1944   a  define an upper plane that is substantially parallel with the lower plane. The thickness of the outboard structure  240  resulting therefrom is that between the lower and upper planes defined by the lower edges  2042   b  and the upper edges  2044   b  of the lower protrusions  1942   a  and the upper protrusions  1944   a.    
     Adhesive beads (e.g., upper adhesive beads  1274 ) are positioned between the lower protrusions  1942   a  and the upper protrusions  1944   a  in the manner described previously. As shown in  FIGS. 21 and 22 , the upper adhesive beads  1274  are positioned on the upper surface  644  between the upper protrusions  1944   a  of the outboard structure  240 . As the upper plate  234  is positioned on the upper adhesive beads  1274  and the upper edges  2044   b  of the upper protrusions  1944   a  engage the upper plate  234 , the adhesive thereof spreads laterally between the upper protrusions  1944   a  by varying amounts depending on the vertical gap between the upper plate  234  (i.e., at the upper plane formed by the upper edges  2044   b  of the upper protrusions  1944   a ) and the upper surface  644 . Lower adhesive beads  1173  (not shown) may be similarly positioned and spread between the lower protrusions  1942   a . The upper floor subassembly  2230 , which incorporates the outboard structures  1940 , may be assembled in accordance with the process described with respect to  FIG. 18 , or suitable variation thereof. 
     With reference to  FIGS. 23-24 , as referenced above, the outboard structures  1940  are machined to form the lower edges  2042   b  and the upper edges  2044   b  of the lower protrusions  1942   a  and the upper protrusions  1944   a  with parallel lower and upper planes. Each outboard structure  1940  is fed into a cutting machine  2300  having a plurality of lower blades  2301  corresponding in number to the plurality of lower protrusions  1942   a  and which rotate about a common axis, such as being coupled to a lower rigid shaft  2302 . The machine additionally includes a plurality of upper blades  2303  corresponding in number to the plurality of upper protrusions  1944   a , which rotate about another common axis, such as being coupled to an upper rigid shaft  2304 . The lower rigid shaft  2302  and the upper rigid shaft  2304  are spaced apart, such that tips of the lower blades  2301  and the upper blades  2303  are spaced apart a distance to achieve a desired thickness of the outboard structure  1940 . As each outboard structure  1940  is fed through the cutting machine  2300  (e.g., between rollers  2305 ), the lower blades  2301  and the upper blades  2303  remove material from the lower protrusions  1942   a  and the upper protrusions  1944   a  to form the lower edges  2042   b  and the upper edges  2044   b  defining the lower and upper planes. The thickness of the outboard structure  1940  resulting therefrom (i.e., between the lower and upper planes defined by the lower edges  2042   b  and the upper edges  2044   b ) may, for example, be substantially equal to the thickness of the core  236 . 
     As referenced above, alternative upper floor subassemblies may be configured substantially similar to the upper floor subassemblies  230 ,  1230 , and  2230  discussed above but which include a lower plate, upper plate, and core with varying thicknesses, as opposed to the lower plate  232 , the upper plate  234 , and/or the core  236  having constant thicknesses. The resultant upper floor subassemblies may still have a substantially constant thickness and a planar upper surface, or may vary slightly in thickness to have a slightly curved or staggered upper surface. 
     With reference to  FIG. 25 , which is a cross-sectional detail view similar to  FIG. 6 , an upper floor subassembly  2530  includes a lower plate  2532 , an upper plate  2534 , a core  2536 , and an outboard structure  2540 . The upper floor subassembly  2530  additionally includes a second outboard structure on its right (not shown) and may also include a forward structure and a rearward structure (not shown; refer to the discussion of the forward structure  238  and the rearward structure  239  above). As compared to the upper floor subassembly  230 , the lower plate  2532  and the upper plate  2534  are configured to bear a greater portion of outboard loading than the lower plate  232  and the upper plate  234 , and the outboard structure  2540  bears a lesser portion of the outboard loading than the outboard structure  240 . In particular, the lower plate  2532  and the upper plate  2534  have a greater thickness at outboard regions thereof as compared to the lower plate  232  and the upper plate  234 , respectively, while the outboard structure  2540  has a lesser thickness than the outboard structure  240 . The upper floor subassembly  2530  has the same or comparable thickness as the upper floor subassembly  230 . The outboard structure  2540  may also have a lesser width (e.g., approximately 50 mm) than the outboard structure  240 , and correspondingly changed ratios of width to thickness and to length. 
     The lower plate  2532  thins in a stepped fashion moving in an inboard direction. For example, the lower plate  2532  may have regions of four different thicknesses on its left side (shown) and on its right side (not shown). An outboard region  2532   a  is the thickest region (e.g., having a thickness of approximately 6 mm and a width of approximately 75 mm). A first inboard region  2532   b  is adjacent the outboard region  2532   a  and is the next thickest (e.g., having a thickness of approximately 4.5 mm and a width of approximately 75 mm). A second inboard region  2532   c  is adjacent the first inboard region  2532   b  and is the next thickest (e.g., having a thickness of approximately 3.0 mm and a width of approximately 75 mm). An innermost region is adjacent to the second inboard region  2532   c  and an opposite second inboard region (not shown), and is the thinnest region (e.g., having a thickness of approximately 1.5 mm and a width of approximately 600 mm). 
     The upper plate  2534  similarly includes an outboard region  2534   a , a first inboard region  2534   b , a second inboard region  2534   c , and an innermost region  2534   d  of corresponding thicknesses and lateral positioning. According to other embodiments, the lower plate  2532  and the upper plate  2534  may include more or fewer regions of different thicknesses, have regions of different thicknesses (e.g., more or less than 6.0 mm, 4.5 mm, etc.), and/or have different widths (e.g., the various regions have widths that are more or less than 75 mm and/or different from each other). 
     The core  2536  includes regions of various thicknesses that correspond to the varying thicknesses of the lower plate  2532  and the upper plate  2534 , such that the upper floor subassembly  2530  may have a substantially constant thickness. For example, the core  2536  may include an outboard region  2536   a  that is laterally adjacent to and/or coupled to the outboard structure  2540 , is positioned vertically between the outboard regions  2532   a ,  2534   a  of the lower plate  2532  and the upper plate  2534 , respectively, and is the thinnest (e.g., 13 mm). A first inboard region  2536   b  is positioned laterally adjacent to the outboard region  2536   a , is positioned vertically between the first inboard regions  2532   b ,  2534   b  of the lower plate  2532  and the upper plate  2534 , respectively, and is the next thinnest (e.g., 16 mm). A second inboard region  2536   c  is positioned laterally adjacent to the first inboard region  2536   b , is positioned vertically between the second inboard regions  2532   c ,  2534   c  of the lower plate  2532  and the upper plate  2534 , respectively, and is the next thinnest (e.g., 19 mm). Finally, an innermost region  2536   d  is positioned laterally adjacent to the second inboard region  2536   c , is positioned vertically between the second inboard regions  2532   c ,  2534   c  of the lower and upper plates  2532 ,  2534 , respectively, and is the thickest (e.g., 22 mm). The core  2536  is made of a material as described previously for the core  236  (e.g., honeycomb structure, foam, wood, etc.). 
     Each of the lower plate  2532  and the upper plate  2534  may be manufactured with varying thicknesses according to various methods. For simplicity, the various methods that follow are discussed with reference only to the lower plate  2532 , or variations thereof, but are also applicable for manufacturing the upper plate  2534 . 
     In a first method, the lower plate  2532  is machined or milled from a single sheet or blank of material (e.g., 2024, 6062, or 7075 aluminum). The blank has a constant thickness equal to that of the thickest region (e.g., the outboard region  2532   a ). The blank has a peripheral shape equal to that of the finished upper floor subassembly  2530 , or of the dimensions of the sandwich structure composite prior to machining to achieve the final dimensions of the finished upper floor subassembly  2530 . The blank is machined or milled (e.g., via a chemical milling process) to achieve regions of desired thickness. 
     In a second method, the lower plate  2532  is rolled from one or more sheets or blanks of material. During a strip rolling process, one or more rollers presses the blank as it is moved past the rollers, thereby causing the material to flow generally perpendicular to the rolling direction, which thins and widens the blank in the region being pressed. The rollers may be arranged successively and in overlapping regions, so as to flow the material outwardly to achieve a region of desired thickness and width. Multiple blanks may thereafter be coupled together at their edges (e.g., via spin welding) to form the lower plate  2532 . 
     The strip rolling process, by itself, provides a cross-sectional profile that is constant along the length (i.e., in the fore-aft direction) of the lower plate  2532 . However, the blanks and/or the lower plate  2532  before and/or after the strip rolling process may undergo a flexible rolling process in which rollers vary pressure applied to the blanks as they pass, which achieves variable thickness along the length of the lower plate  2532 . 
     With reference to  FIG. 26 , as an alternative to the lower plate  2532  being formed from a continuous blank, a lower plate  2632  may be formed from one or more sheets of material that are overlaid and coupled to each other to achieve regions of desired thickness and width. A left side of the lower plate  2632  includes an outboard region  2632   a , a first inner region  2632   b , a second inner region  2632   c , and an innermost region  2632   d  that step down in thickness (refer above to the discussion of the lower plate  2532  and its regions  2532   a ,  2532   b ,  2532   c , and  2532   d ). The various regions are formed by a lower sheet  2632   e , a first inner sheet  2632   f , a second inner sheet  2632   g , and an innermost sheet  2632   h , which have different widths and are stacked on top of and coupled to each other (e.g., bonded or adhered to each other using an adhesive). The sheets  2632   e ,  2632   f ,  2632   g , and  2632   h  may, for example, be formed of blanks of a common material (e.g., 2024, 6062, or 7075 aluminum) and/or common thickness (e.g., 1.5 mm). Alternatively, the sheets  2632   e ,  2632   f ,  2632   g , and  2632   h  may have thicknesses and/or materials different from each other (e.g., different grades or alloys of aluminum). 
     With reference to  FIG. 27 , as another alternative to the lower plate  2532 , a lower plate  2732  may be formed from one or more blanks or sheets of varied thickness that are coupled at their edges to each other to achieve regions of desired thickness and width. A left side of the lower plate  2732  includes an outboard region  2732   a , a first inner region  2732   b , a second inner region  2732   c , and an innermost region  2732   d  that step down in thickness (refer above to the discussion of the lower plate  2532  and its regions  2532   a ,  2532   b ,  2532   c , and  2532   d ). The various regions are formed by an outboard sheet  2732   e , a first inner sheet  2732   f , a second inner sheet  2732   g , and an innermost sheet  2732   h , which are coupled to each other at their edges (e.g., via spin welding). The sheets  2732   e ,  2732   f ,  2732   g ,  2732   h  may, for example, be formed of blanks of a common material (e.g., 2024, 6062, or 7075 aluminum, or other suitable material) and desired varying thickness (e.g., equal increments in thickness), or may be formed of different materials (e.g., different grades or alloys of aluminum). 
     With reference to  FIG. 28 , as an alternative to the upper floor subassembly  2530  in which the outboard structure  2540  is arranged between the outboard regions  2532   a ,  2534   a  of the lower plate  2532  and the upper plate  2534 , an upper floor subassembly  2830  may instead have the outboard regions  2532   a ,  2534   a  of the lower plate  2532  and the upper plate  2534  coupled directly to each other at mating surfaces thereof (e.g., bonded or adhered using an adhesive). The upper floor subassembly  2830 , thereby, omits the outboard structures  2540  from the upper floor subassembly  2530 . The upper floor subassembly  2830  may, instead of including the lower plate  2532  and the upper plate  2534 , include the lower plate  2632  or the lower plate  2732 , and similarly formed upper plates. 
     Referring again to  FIG. 25 , as referenced above, in embodiments of the upper floor subassembly (e.g.,  2530 ,  2830 ) having lower and upper plates (e.g.,  2532  and  2534 ,  2632 ,  2730 ) of varying thickness, the core  2536  also varies in thickness. The regions  2536   a ,  2536   b ,  2536   c ,  2536   d  of the core  2536  having varied thickness may be formed, for example, from a core  2536  that is unitary and machined or otherwise reduced to an appropriate thickness, as is shown in  FIG. 25 . 
     Referring to  FIG. 29 , as a first alternative to the core  2536 , an upper floor subassembly  2930  includes a core  2936  having multiple core members of varying thickness to achieve different regions of varying thickness (refer to the discussion of the regions  2536   a ,  2536   b ,  2536   c ,  2536   d  of the core  2536  above). An outboard region  2936   a  of the core  2936  is formed by an outboard core member  2936   e  that is the thinnest of the core members. A first inner region  2936   b  of the core  2936  is formed by a first inner core member  2936   f  having the next least thickness. A second inner region  2936   c  of the core  2936  is formed by a second inner core member  2936   g  having the next least thickness. Finally, an innermost region  2936   d  of the core  2936  is formed by an innermost core member  2936   h  that is the thickest of the core members. Adjacent core members are coupled to each other with a splice adhesive  2973 . Each of the core members  2936   e ,  2936   f ,  2936   g ,  2936   h  may be formed of materials as described previously (e.g., a honeycomb structure, foam, wood, etc.). As described above with respect to the splice adhesive  763 , the splice adhesive  2973  may be configured to expand into the partial cells of the honeycomb structure forming each of the core members  2936   e ,  2936   f ,  2936   g ,  2936   h.    
     Referring to  FIG. 30 , as a second alternative to the core  2536 , an upper floor subassembly  3030  includes a core  3036  having multiple core members of varying thickness and upper and lower plate members associated with each core member to achieve different regions of varying thickness (refer again to the discussion of the regions  2536   a ,  2536   b ,  2536   c ,  2536   d  of the core  2536  above). An outboard region  3036   a  of the core  3036  is formed by an outboard core member  3036   e  having upper and lower plates  3036   e ′ coupled thereto (e.g., bonded or adhered using adhesives). A first inner region  3036   b  of the core  3036  is formed by a first inner core member  3036   f  having upper and lower plates  3036   f ′ coupled thereto. A second inner region  3036   c  of the core  3036  is formed by a second inner core member  3036   g  having upper and lower plates  3036   g ′ coupled thereto. Finally, an innermost region  3036   d  of the core  3036  is formed by an innermost core member  3036   h  having lower and upper plates  3036   h ′ coupled thereto. Each of the core members  2936   e ,  2936   f ,  2936   g ,  2936   h  may be formed of materials as described previously (e.g., a honeycomb structure, foam, wood, etc.). Each of the plates  3036   e ′,  3036   f ,  3036   g ′,  3036   h ′ may be formed of the same material forming the lower plate  2532  (e.g., 2024, 6062, or 7075 aluminum, or other suitable material), or other suitable sheet material. Adjacent core members are coupled to each other with the splice adhesive  2973 . 
     Referring to  FIG. 31 , as a third alternative to the core  2536 , an upper floor subassembly  3130  includes a core  3136  having multiple core members of different materials to achieve different regions of varying thickness (refer again to the discussion of the regions  2536   a ,  2536   b ,  2536   c ,  2536   d  of the core  2536  above). An outboard core member  3136   e  is, for example, a foam material and forms an outboard region  3136   a , a first inner region  3136   b , and a second inner region  3136   c  of the core  3136  of different thicknesses. An inner core member  3136   f  is, for example, a honeycomb material and forms an inner region  3136   d  of the core  3136  having a constant thickness. The outboard core member  3136   e  may, for example, be injected and cured between the lower plate  2532  and the upper plate  2534  and into the partial cells of the honeycomb structure of the inner core member  3136   f , or may be coupled thereto with a splice adhesive (not shown). 
     Referring to  FIG. 32 , an upper floor subassembly  3230  includes a lower plate  3232  and an upper plate  3234 , which thin in a tapered or gradual fashion moving inboard. A core  3236  thickens in a corresponding tapered or gradual fashion, such that the upper floor subassembly  3230  has a substantially constant thickness. Each of the lower plate  3232  and the upper plate  3234  may, for example, be formed of a tailor rolled blank of suitable material (e.g., 2024, 6062, or 7075 aluminum, or other suitable material) having a thickness that reduces moving inboard from outboard edges thereof, or may be formed from multiple tailor rolled blanks (e.g., blanks that reduce in thickness moving inboard and are welded to each other at inner edges thereof). The lower plate  3232  and the upper plate  3234  may have a constant thickness at inboard locations thereof. The core  3236  may be formed of a single material (e.g., honeycomb structure, foam, wood, etc.), or may include an outboard core member of foam having variable thickness corresponding to the lower plate  3232  and the upper plate  3234  and an inboard core member of a honeycomb structure having a constant thickness and coupled at its edge to the outboard core member (e.g., similar to the core  3136 ). 
     Referring to  FIG. 33 , an upper floor subassembly  3330  includes a lower plate  3332  and an upper plate  3334 , which thin in a stepped (as shown) or tapered (not shown) manner moving inboard. The lower plate  3332  and the upper plate  3334  are, however, spaced apart a constant distance by the core  3336  and the outboard structure  2540 . As a result, the upper floor subassembly  3330  has a variable thickness that reduces gradually moving in an inboard direction, for example, from approximately 25-34 mm at an outboard edge to approximately 16-25 mm at an innermost region. Carpet, fabric, foam, or other materials may be arranged above the upper plate  3334 , so as to camouflage, mask, or otherwise conceal the upper floor subassembly  3330  having a varied thickness and/or non-planar upper surface. 
     The lower plate  3332  and the upper plate  3334  may be manufactured according to the various methods described above for the lower plate  2532  (e.g., machining and/or chemical milling). Alternatively, the lower plate  3332  and/or the upper plate  3334  may be substituted for plates constructed in the manner of the lower plate  2632  (i.e., having sheets stacked on top of and coupled to each other), or the lower plate  2732  (i.e., having sheets of varying thickness that are welded to each other). 
     Referring to  FIG. 34 , according to a still further alternative, the lower plate  3332  and/or the upper plate  3334  may be substituted for a plate  3432 . The plate  3432  is configured with regions  3432   a ,  3432   b ,  3432   c ,  3432   d  of varying thickness (refer to the discussion of regions  2532   a ,  2532   b ,  2532   c , and  2532   d  of the lower plate  2532  above). The plate  3432  includes a base or innermost sheet  3432   e , which forms the thickness of the innermost region  3432   d  of the plate  3432  and may span the width of the upper floor subassembly  3330 . The plate  3432  additionally includes an outboard sheet  3432   f , a first inner sheet  3432   g , and a second inner sheet  3432   h , which are of decreasing thickness (e.g., 4.5 mm, 3 mm, and 1.5 mm, respectively). The sheets  3432   f ,  3432   g ,  3432   h  are welded together at adjacent edges thereof, and are stacked on top of and coupled to the base sheet  3432   e  (e.g., bonded or adhered thereto with an adhesive). The base sheet  3432   e  may, for example, be made from a higher grade and/or more expensive material (e.g., aluminum alloy) than each of the outboard sheet  3432   f , the first inner sheet  3432   g , and the second inner sheet  3432   h.    
     Referring to  FIG. 35 , according to a still further embodiment, an upper floor subassembly  3530  includes outboard structures  3540  having variable thickness (e.g., narrowing in a stepped fashion moving inboard). The lower plate  3532  and the upper plate  3534  are configured with variable thickness to receive a portion (as shown) or all of the outboard structure  3540  therebetween, such that the upper floor subassembly  3530  has a constant thickness. The lower plate  3532  may, for example, be formed from a plurality of sheets stacked on top of and coupled to each other and the outboard structure  3540 . In particular, a base sheet  3532   a  is coupled to a lower surface of a thin portion of the outboard structure  3540 . A first inner sheet  3532   b , a second inner sheet  3532   c , and a third inner sheet  3532   d  of varying widths are stacked on top of and coupled to each other and the base sheet  3532   a , and also abut and/or are coupled to an inward edge of the outboard structure  3540  (e.g., with an adhesive). In this manner, the lower plate  3532  varies in thickness, thinning in a stepped manner moving inboard from the outboard structure  3540 . The upper plate  3534  is configured similar to the lower plate  3532 . The core  3536  may be configured with variable thickness in the various manners described previously for other cores (e.g.,  2536 ,  2936 ,  3036 ,  3136 ). 
     Other embodiments of upper floor subassemblies having lower and upper plates that thin gradually, similar to the lower plate  3232 , are depicted in  FIGS. 36-38 . As shown in  FIG. 36 , an upper floor subassembly  3630  includes lower and upper plates  3632 ,  3634  having flat outer surfaces and curved (or otherwise tapered) inner surfaces. The upper floor subassembly  3630  additionally includes a core  3636  (e.g., a multicomponent core) having an outboard core member of foam that tapers, and an inboard core member of a honeycomb structure of constant thickness. The lower and upper plates  3632 ,  3634  and the core  3636  abut and/or are coupled to an inward edge of the outboard structure  3640 . 
     As shown in  FIG. 37 , an upper floor subassembly  3730  includes lower and upper plates  3732 ,  3734  having curved (or otherwise tapered) outer surfaces and curved (or otherwise tapered) inner surfaces. The upper floor subassembly  3730  additionally includes a core  3736  (e.g., a multicomponent core) having an outboard core member of foam that tapers, and an inboard core member of a honeycomb structure of constant thickness. The lower and upper plates  3732 ,  3734  and the core  3736  abut and/or are coupled to an inward edge of the outboard structure  3740 . 
     As shown in  FIG. 38 , an upper floor subassembly  3830  includes lower and upper plates  3832 ,  3834  having curved (or otherwise tapered) outer surfaces and flat lower surfaces. The upper floor subassembly  3830  additionally includes a single component core  3836  of a honeycomb structure of constant thickness. The lower and upper plates  3732 ,  3734  and the core  3736  abut and/or are coupled to an inward edge of the outboard structure  3740 . 
     For each of the embodiments discussed above, prior to assembling the lower plate and/or upper plate into the finished upper floor subassemblies, the plates may be subject to further treatments, such as heat treatment (e.g., to strengthen weld joints between blanks or sheets), solution heat treatment, quenching, annealing, galvanizing, coating, or other finished treating. Those plates that include adhesives, depending on the adhesive properties, may not be subject to certain further treatments. 
     Each embodiment of the upper floor subassemblies discussed in conjunction with  FIGS. 25-38 , which include various plate and core configurations with varied thicknesses, may be assembled according to the methods previously described with respect to  FIG. 9  and  FIG. 18  or variations thereof. For example, film adhesive, adhesive beads, and/or splice adhesives may be used in conjunction with heating and pressing as may be appropriate to couple (e.g., substantially continuously couple) mating surfaces of their respective components. 
     Referring to  FIG. 39 , according to yet a still further embodiment, an upper floor structure  3930  includes outboard structures  3940  and inboard structures  3950  that are welded together at adjacent edges. The outboard structures  3940  may, for example, be extrusions that have greater stiffness (e.g., due to geometry or gauge) bending about a vertical axis than the inboard structures  3950 . The outboard structures  3940  and/or the inboard structures  3950  may, for example, be extrusions of an aluminum material. 
     Referring to  FIGS. 1, 3, 4, and 40-43 , the sill assembly  102  is positioned generally outboard of and is coupled to the lower floor subassembly  218  and the upper floor subassembly to form the inner floor assembly  110 . The sill assembly  102  is configured to absorb energy and distribute force to the inner floor assembly  110  arising from an outboard loading event. For example, the sill assembly  102  is configured to plastically deform to absorb energy, and engages the upper floor subassembly  230  and the lower floor subassembly  218  to transfer force thereto. As noted previously, the upper floor subassembly  230  is configured with stiff outboard regions to resist or limit bending or deformation about vertical axes. The lower floor subassembly  218  is, by being a generally continuous plate member, also able to resist or limit bending or deformation about vertical axes. Thus, the sill assembly  102 , in conjunction with the upper floor subassembly  230  and the lower floor subassembly  218 , helps prevent intrusion into the compartments  223  of the intermediate floor subassembly  220 , collapse of the compartments  223 , and/or impact with the one or more batteries  224  from an outboard loading event. 
     The sill assembly  102  may be configured to efficiently absorb energy over a collapsible width (e.g., stroke) thereof in the inboard-outboard direction, while limiting peak observed forces. More particularly, with energy absorbed being equal to the force observed times a duration of a loading event (e.g., the area under a curve of a force vs. time plot), the sill assembly  102  is configured to quickly elevate and maintain the level of forces observed over the duration of the outboard loading event (e.g., reaching a nearly square force vs. time plot), while limiting peak observed forces. To this end, the sill assembly  102  is tuned with compressive strength in the inboard-outboard direction (i.e., inboard or lateral compressive strength) that may vary at different locations moving inboard-outboard, fore-aft, and up/down (i.e., different inboard-outboard locations, different fore-aft locations, and/or different vertical locations), such as by increasing in inboard compressive strength moving outboard, decreasing moving in a fore-aft direction away from a central fore-aft location corresponding to a center of gravity of the vehicle, and/or increasing moving upward. Inboard or lateral compressive strength is the local and/or regional capacity (e.g., of a region, structure, or member of the sill  102 ) to withstand loading that originates from an outboard location relative to the vehicle  100  or sill assembly  102  and is applied to the sill in an inboard direction that is substantially horizontal and substantially perpendicular to a direction of travel of the vehicle  100 . The sill assembly  102  may additionally have bending stiffness about vertical axes that increases moving outboard. Bending stiffness or flexural rigidity about vertical axes is that capacity (e.g., of a region, structure, or member of the sill  102 ) to resist against bending deformation thereof about a vertical axis, and may also be referred to as horizontal bending stiffness. 
     The inboard compressive strength and/or bending stiffness of the sill assembly  102  may vary at different inboard-outboard locations, so as to more efficiently absorb and distribute loading over a collapsible width (e.g., stroke) of the sill assembly  102  in the inboard-outboard direction, while minimizing peak observed forces. By having greater bending stiffness about vertical axes moving outboard (e.g., in adjacent inboard/outboard regions that extend in the fore-aft direction, such as a majority (e.g., 50% or more) or substantial majority (e.g., 75% or more) of a fore-aft length of the sill  102 ), outboard portions of the sill assembly  102  spread and distribute force from outboard loading to inboard portions of the sill assembly  102 . By additionally having decreasing inboard compressive strength moving inboard (e.g., in adjacent inboard/outboard locations or in adjacent inboard/outboard regions extending in the fore-aft direction, such as majority (e.g., 50% or more) or substantial majority (e.g., 75% or more) of a fore-aft length of the sill  102 ), the weaker inboard portions of the sill assembly  102  absorb energy by more fully deforming (e.g., collapsing) earlier in an inboard direction (e.g., compressible width) across a greater fore-aft distance (e.g., length) than the stronger outboard portions, which may reduce peak observed forces. 
     The compressive strength of the sill assembly  102  may also vary at different fore-aft locations. For example, the sill assembly  102  may be compressively stronger at a fore-aft location corresponding to a center of gravity of the vehicle  100  and compressively weaker forward and/or rearward thereof. Off-center outboard loading results in more energy transfer to kinetic rotation of the vehicle  100  than on-center outboard loading, which lessens the amount of energy to be absorbed by deformation of the sill assembly  102 . Thus, the sill assembly  102  may be tuned with less compressive strength at off-center locations to deform more fully over the collapsible width of the sill assembly  102  and, thereby, reduce peak observed forces with off-center outboard loading. 
     The compressive strength of the sill assembly  102  may also vary at different vertical locations. For example, the sill assembly  102  may be compressively stronger at upper locations than at lower locations to distribute more force from outboard loading to the upper floor subassembly  230  than to the lower floor subassembly  218 , which may be less capable of absorbing energy and/or distributing forces from outboard loading than the upper floor subassembly  230 . 
     Referring to  FIGS. 40-42B , the sill assembly  102  is divided into an intermediate sill region  4202   a  (e.g., a first, primary, and/or energy-absorbing region or portion), an inboard sill region  4202   b  (e.g., a second and/or coupling region or portion), and/or an outboard sill region  4202   c  (e.g., a third and/or force-spreading region or portion), which extend in a fore-aft direction of the vehicle and include various components as discussed in further detail below. 
     The intermediate sill region  4202   a  is configured to deform (e.g., collapse, compress, etc.) in an inboard direction to absorb energy from the outboard loading, as well as engage the inner floor assembly  110  (e.g., the upper floor subassembly  230  and the lower floor subassembly  218 ) to transfer force from the outboard loading thereto (e.g., around the intermediate floor subassembly  220  and the batteries  224  contained thereby). The intermediate sill region  4202   a  may be laterally divided into two or more subregions having different compressive strength and/or bending characteristics to absorb energy and/or distribute forces in different manners (e.g., to limit peak observed forces as described above). For example, as shown, the intermediate sill region  4202   a  may include an outboard subregion  4202   a ′ (e.g., first subregion) and an inboard subregion  4202   a ″ (e.g., second subregion). The outboard subregion  4202   a ′ has greater inboard compressive strength than the inboard subregion  4202   a ″ at proximate (e.g., adjacent) locations and/or elongated regions (e.g., majority or substantial majority of the fore-aft length of the sill  102 , as described above) thereof, which allows the inboard subregion  4202   a ″ to deform (e.g., collapse) to absorb energy earlier than the outboard subregion  4202   a ′. Additionally, the outboard subregion  4202   a ′ may have greater bending stiffness about a vertical axis than the inboard subregion  4202   a ″ (e.g., in adjacent regions extending a majority or substantial majority of the fore-aft length of the sill  102 ) by which the outboard subregion  4202   a ′ spreads force in a fore-aft direction along and inboard to the inboard subregion  4202   a ″. In other embodiments, the intermediate sill region  4202   a  may include more laterally divided subregions that also increase in compressive strength and bending stiffness moving in an outboard direction. 
     The inboard sill region  4202   b  is arranged inboard of the intermediate sill region  4202   a  and is configured to couple the sill assembly  102  to the inner floor assembly  110 . 
     The outboard sill region  4202   c  is arranged outboard of the intermediate sill region  4202   a  and is configured to distribute localized force from outboard loading across the intermediate sill region  4202   a . More particularly, the outboard sill region  4202   c  includes or is configured to removably receive (e.g., receive various members of movable door structures) members or assemblies that have greater compressive strength and/or have greater bending stiffness about vertical axes, compared to the intermediate sill region  4202   a  (e.g., in adjacent locations and/or regions extending a majority or substantial majority of the fore-aft length of the sill  102 ). As such, the outboard sill region  4202   c  distributes force in a fore-aft direction across the intermediate sill region  4202   a , such that the intermediate sill region  4202   a  absorbs energy by more fully deforming prior to the outboard sill region  4202   c.    
     The intermediate sill region  4202   a , the inboard sill region  4202   b , and the outboard sill region  4202   c  are formed by various components and/or structures of the sill assembly  102 . The sill assembly  102  includes an outboard load structure  4003  (e.g., first load transfer or energy absorbing structure or member), as well as an upper inboard load structure  4004  (e.g., second load transfer structure or member) and a lower inboard load structure  4005  (e.g., third load transfer structure or member), which form the intermediate sill region  4202   a . The sill assembly  102  additionally includes an outer casing  4006  (e.g., outer sill shell or casing) that substantially surrounds the outboard load structure  4003 , the upper inboard load structure  4004 , and the lower inboard load structure  4005 , and which may form the inboard sill region  4202   b  of the sill assembly  102 . The sill assembly  102  may additionally include an outboard partition  4007   a  (e.g., first partition, divider, planar, or sheet structure or member) and an inboard partition  4008   a  (e.g., second partition, divider, planar, or sheet structure or member) between the various regions/subregions and structures of the sill assembly  102 . 
     The outboard load structure  4003  is, for example, a stamped aluminum member having a plurality of corrugations  4003   a  (e.g., outboard corrugations). The corrugations  4003   a  include upright segments  4003   b  that extend between upper segments  4003   c  and lower segments  4003   d  thereof. The upright segments  4003   b , the upper segments  4003   c , and the lower segments  4003   d  may each be planar segments (as shown), which extend substantially perpendicular to a fore-aft direction of the vehicle  100  (e.g., within ten degrees of perpendicular). According to other embodiments, the corrugations  4003   a  may be configured in other manners, for example, by including curved segments, including a combination of curved and planar segments, and/or extending at different angles relative to the fore-aft direction of the vehicle  100 . 
     The outboard load structure  4003  is additionally configured to have varying inboard compressive strength at different fore-aft locations along a length thereof. For example, as shown in  FIGS. 40 and 43 , the corrugations  4003   a  have different densities with the upright segments  4003   b  being positioned closer to each other (e.g., by having upper segments  4003   c  and/or lower segments  4003   d  that are shorter in length), which results in different densities of material and resultant inboard compressive strength at various locations of the outboard load structure  4003 . For example, as shown in  FIG. 41 , the corrugations  4003   a  have two different densities, being less dense with resultantly lesser inboard compressive strength in a forward region (left as shown) and being more dense with resultantly greater inboard compressive strength in a rearward region (right as shown). According to other embodiments, the outboard load structure  4003  may be provided with varying stiffness in other manners, for example, by having different wall thicknesses (e.g., gauges of the segments  4003   b ,  4003   c ,  4003   d ) at different locations and/or by varying in stiffness in a more progressive manner (e.g., having progressively decreasing stiffness or density moving away from the lateral position of the center of gravity of the vehicle  100 ). 
     The outboard load structure  4003  may be provided in other forms. For example, the outboard load structure  4003  may instead comprise multiple components (e.g., multiple aluminum stampings), be formed from different manufacturing methods (e.g., extruding, molding, etc.), be formed from different materials (e.g., steel, metallic or non-metallic foams, or plastics, such as PA6, reinforced with carbon or glass), have different shapes (e.g., a honeycomb structure or other structure having a substantially uniform cross-sectional shape, or an egg-crate structure or other structure having a non-uniform cross-sectional shape), etc. 
     The outboard partition  4007   a  is coupled to and supports the outboard load structure  4003 . The outboard partition  4007   a  is located between the outboard subregion  4202   a ′ and the inboard subregion  4202   a ″ of the intermediate sill region  4202   a  of the sill assembly  102 . The outboard partition  4007   a  is a generally planar member (e.g., stamped aluminum) to which is coupled an inboard side or edges of the outboard load structure  4003 . For example, the outboard load structure  4003  may be coupled to the outboard partition  4007   a  via adhesive bonding, spot welding, or any other suitable coupling method. During an outboard loading event, friction between the outboard load structure  4003  and the outboard partition  4007   a  (e.g., due to compression therebetween) may additionally function to maintain the outboard load structure  4003  in a generally fixed position relative to the outboard partition  4007   a . As discussed in further detail below, the outboard partition  4007   a  additionally functions to locate the outboard load structure  4003  within the sill assembly  102  and the inner floor assembly  110 , including relative to the upper inboard load structure  4004  and the lower inboard load structure  4005 . The outboard partition  4007   a  may also function as a bearing (e.g., load distributor) between the outboard load structure  4003  and the upper inboard load structure  4004  and the lower inboard load structure  4005 , as well as to couple upper and lower portions of the outer casing  4006  to each other and prevent separation therebetween. 
     The upper inboard load structure  4004  and the lower inboard load structure  4005  are located in the inboard subregion  4202   a ″ of the intermediate sill region  4202   a  of the sill assembly  102 . The upper inboard load structure  4004  is positioned in an upper subregion  4202   d  of the sill assembly  102 . The upper inboard load structure  4004  is spaced above and forms a vertical gap with the lower inboard load structure  4005 , which is in a lower subregion  4202   e  of the sill assembly  102 . The upper inboard load structure  4004  and the lower inboard load structure  4005  are each stamped aluminum members having corrugations  4004   a ,  4005   a , respectively (e.g., inboard corrugations, or upper and lower inboard corrugations, respectively). The corrugations  4004   a ,  4005   a  may be configured similar to the corrugations  4003   a  of the outboard load structure  4003  by having upright segments  4004   b ,  4005   b  that extend between upper segments  4004   c ,  4005   c  and lower segments  4004   d ,  4005   d , such segments being planar (as shown), extending substantially perpendicular to a fore-aft direction of the vehicle  100 , and having varying stiffness along a fore-aft direction (e.g., due to increasing density and/or material thickness). The corrugations  4004   a ,  4005   a , however, extend shorter vertical distances and are less stiff than the corrugations  4003   a  of the outboard load structure  4003 . 
     Furthermore, the upper inboard load structure  4004  and the lower inboard load structure  4005  may be configured relative to each other to absorb energy and to distribute force from outboard loading to the upper floor subassembly  230  and the lower floor subassembly  218 . For example, the upper inboard load structure  4004  (and thereby the upper subregion  4202   d ) has different (e.g., greater or lesser) inboard compressive strength than the lower inboard load structure  4005  (and thereby the lower subregion  4202   e ), so as to distribute more force to the upper floor subassembly  230  than the lower floor subassembly  218  or vice versa. For example, the upper inboard load structure  4004  may be configured to transfer between approximately 60% and 75% of inboard loading to the upper floor subassembly  230  and the lower inboard load structure  4005  may be configured to transfer the remaining force (e.g., 25% to 40% of the inboard loading) to the lower floor subassembly  218 , or vice versa. The distribution of force between the upper inboard load structure  4004  and the lower inboard load structure  4005  may, for example, be configured according to the height of the inboard loading relative to the upper floor subassembly  230  and the lower floor subassembly  218 , and the relative strengths of the upper floor subassembly  230  and the lower floor subassembly  218  (e.g., to prevent buckling thereof), and may be adjusted according to the compressive strengths of the upper inboard load structure  4004  and the lower inboard load structure  4005 . 
     One or more of the upper inboard load structure  4004  and the lower inboard load structure  4005  may be configured in the alternative manners described above for the outboard load structure  4003 , including instead comprising multiple components (e.g., multiple aluminum stampings), being formed from different manufacturing methods (e.g., extruding, molding, etc.), being formed from different materials (e.g., steel, metallic or non-metallic foams, or plastics, such as PA6 reinforced with carbon or glass), having different shapes (e.g., a honeycomb structure or other structure having a substantially uniform cross-sectional shape, or an egg-crate structure or other structure having a non-uniform cross-sectional shape), etc. The upper inboard load structure  4004  and the lower inboard load structure  4005  may instead be provided as a unitary structure, for example, by having upper and lower load regions that are interconnected by an intermediate web or other structure. 
     The inboard partition  4007   b  is coupled to the upper inboard load structure  4004  and the lower inboard load structure  4005 . The inboard partition  4007   b  is located between the inboard sill region  4202   b  and the intermediate sill region  4202   a . The inboard partition  4007   b  is configured similar to the outboard partition  4007   a  as a generally planar member (e.g., stamped aluminum) to which is coupled an inboard side or edges of the upper inboard load structure  4004  and the lower inboard load structure  4005 . For example, the upper inboard load structure  4004  and the lower inboard load structure  4005  may be coupled to the inboard partition  4007   b  via adhesive bonding, spot welding, or any other suitable coupling method. During an outboard loading event, friction of the upper inboard load structure  4004  and the lower inboard load structure  4005  with the inboard partition  4007   b  (e.g., due to compression therebetween) may additionally function to maintain the upper inboard load structure  4004  and the lower inboard load structure  4005  in generally fixed positions relative to the inboard partition  4007   b.    
     As discussed in further detail below, the inboard partition  4007   b  may, like the outboard partition  4007   a , additionally function to locate the upper inboard load structure  4004  and the lower inboard load structure  4005  within the sill assembly  102  and the inner floor assembly  110 , including relative to the upper floor subassembly  230  and the lower floor subassembly  218 . The inboard partition  4007   b  may also function as a bearing (e.g., load distributor) between the upper inboard load structure  4004  and the upper floor subassembly  230 , as well as between the lower inboard load structure  4005  and the lower floor subassembly  218 . The inboard partition  4007   b  also couples upper and lower portions of the outer casing  4006  to each other and prevents separation therebetween. 
     The outboard load structure  4003  is configured to transfer force from outboard loading to the upper inboard load structure  4004  and the lower inboard load structure  4005 , which in turn transfer force to the upper floor subassembly  230  and the lower floor subassembly  218 , respectively. As shown in  FIG. 42A , the outboard load structure  4003  is in close lateral proximity (i.e., in an inboard-outboard direction) with the upper inboard load structure  4004  and the lower inboard load structure  4005  (e.g., with the outboard partition  4007   a , and a minimal or no gap therebetween), such that outboard loading is nearly immediately transferred to the upper inboard load structure  4004  and the lower inboard load structure  4005 . The upper inboard load structure  4004  and the lower inboard load structure  4005  are similarly in close lateral proximity to the upper floor subassembly  230  and the lower floor subassembly  218 , respectively, such as with the inboard partition  4007   b  therebetween and a minimal gap (e.g., to facilitate assembly while accounting for manufacturing variability). 
     Furthermore, the outboard load structure  4003  is configured to have greater inboard compressive strength and/or bending stiffness about a vertical axis than the upper inboard load structure  4004  and the lower inboard load structure  4005  individually and cooperatively (e.g., at corresponding/adjacent locations and/or elongated regions thereof extending a majority or substantial majority of the fore-aft length of the sill  102 ), which as described above, spreads outboard loading from the outboard load structure  4003  to the upper inboard load structure  4004  and the lower inboard load structure  4005 , which deform more fully first. 
     Referring to  FIGS. 42A-43 , the outboard load structure  4003  also vertically overlaps the upper inboard load structure  4004  and the lower inboard load structure  4005  vertically. The corrugations  4003   a  of the outboard load structure  4003  cross or overlap the corrugations  4004   a  of the upper inboard load structure  4004  and the corrugations  4005   a  of the lower inboard load structure  4005 . The upper inboard load structure  4004  and the lower inboard load structure  4005  in turn vertically overlap the upper floor subassembly  230  and the lower floor subassembly  218  (or a member  4218   a  thereof, discussed further below), respectively. These vertically overlapping and crossing relationships allow the force from outboard loading to be transferred in an inboard-outboard direction from the outboard load structure  4003 , through the upper inboard load structure  4004  and the lower inboard load structure  4005 , to the upper floor subassembly  230  and the lower floor subassembly  218 . 
     More particularly, the outboard load structure  4003  (e.g., the corrugations  4003   a  thereof) extends upward into the upper subregion  4202   d  of the sill assembly  102 , such that an upper end of the outboard load structure  4003  (e.g., the upper segments  4003   c  thereof) is at a vertical position above a lower end of the upper inboard load structure  4004  (e.g., formed by the lower segments  4004   d  and/or portions of the upright segments  4004   b  of the corrugations  4004   a  thereof). Portions of the upright segments  4003   b  of the outboard load structure  4003  may also be at vertical positions above the lower end of the upper inboard load structure  4004 . In this manner, the outboard load structure  4003  vertically overlaps the upper inboard load structure  4004 . The vertical position of the upper end of the outboard load structure  4003  may also be above (e.g., vertically overlaps) a lower end of the upper floor subassembly  230  (as shown), or may be at a vertical position below the lower end of the upper floor subassembly  230  such that the upper inboard load structure  4004  spans a vertical distance between the upper end of the outboard load structure  4003  and the upper floor subassembly  230 . 
     The upper inboard load structure  4004  also extends upward, such that an upper end thereof (e.g., formed by the upper segments  4004   c  and/or portions of the upright segments  4004   b ) is at a vertical position above a lower end of the upper floor subassembly  230  (e.g., the outboard edge  330   a  thereof). In this manner, the upper inboard load structure  4004  vertically overlaps the upper floor subassembly  230 . 
     The outboard load structure  4003  (e.g., the corrugations  4003   a  thereof) also extends downward into the lower subregion  4202   e  of the sill assembly  102 , such that a lower end of the outboard load structure  4003  (e.g., the lower segments  4003   d  thereof) is at a vertical position below an upper end of the lower inboard load structure  4005  (e.g., formed by the upper segments  4005   c  and/or portions of the upright segments  4005   b  of the corrugations  4005   a  thereof). Portions of the upright segments  4003   b  may also be at vertical positions below the upper end of the lower inboard load structure  4005 . In this manner, the outboard load structure  4003  vertically overlaps the lower inboard load structure  4005 . The vertical position of the lower end of the outboard load structure  4003  may be above an upper end of the lower floor subassembly  218  (or the member  4218   a  thereof; as shown) such that the lower inboard load structure  4005  spans a vertical distance between the lower segments  4003   d  and the lower floor subassembly  218 , or may be at a vertical position below the upper end of the lower floor subassembly  218 . 
     The lower inboard load structure  4005  in turn extends downward, such that the lower end thereof (e.g., formed by the lower segments  4004   d  and/or portions of the upright segments  4004   b ) is at a vertical position below an upper end of the lower floor subassembly  218 . For example, the lower floor subassembly  218  includes one or more of the members  4218   a  fixedly coupled at an outboard edge thereof, which forms an upright bearing surface that receives thereagainst force from the lower inboard load structure  4005 . The members  4218   a  are elongated (e.g., extruded) to extend in the fore-aft direction. In this manner, the lower inboard load structure  4005  vertically overlaps the lower floor subassembly  218 . 
     Furthermore, the vertical spacing between the upper and lower inboard load structures  4005  allows force to be distributed upward and downward to the upper floor subassembly  230  and the lower floor subassembly  218  around (i.e., above and below) intermediate floor subassembly  220 , including the compartments  223  containing the batteries  224 . As a result, substantially greater amounts of force are transferred to the upper floor subassembly  230  and the lower floor subassembly  218  than to the intermediate floor subassembly  220 . For example, as shown in  FIG. 42B , a force F from outboard loading is distributed upward and inboard from the beam structure  4011  (discussed in further detail below), through the outboard load structure  4003 , through the upper inboard load structure  4004 , and to the upper floor subassembly  230 . Similarly, the force F is distributed downward and inboard from the beam structure  4011 , through the outboard load structure  4003 , through the lower inboard load structure  4005 , and to the lower floor subassembly  218 .  FIG. 42C  is a simplified cross-sectional drawing of the sill assembly  102  illustrating force transfer to the upper floor assembly  230  and the lower floor subassembly  218 .  FIG. 42D  depicts an alternative sill assembly  4202  in which the outboard load structure  4003  extends further downward to overlap the lower floor subassembly  218  for more direct load transfer and/or otherwise includes the outer sill structure  4200   a  with a tighter radius transitioning from below the sill assembly  4202  to upward alongside the sill assembly  4202 . 
     As shown in  FIG. 43 , the corrugations  4003   a  of the outboard load structure  4003  cross the corrugations  4004   a  of the upper inboard load structure  4004  at point locations that are below (e.g., at a lower elevation) than the upper floor subassembly  230 . The corrugations  4003   a  of the outboard load structure  4003  also cross the corrugations  4005   a  of the lower inboard load structure  4005  at point locations that are above (e.g., at a higher elevation) than the lower floor subassembly  218  (e.g., the member  4218   a  thereof). The outboard partition  4007   a  is arranged between the outboard load structure  4003  and the upper inboard load structure  4004 , as well as the lower inboard load structure  4005 . The outboard partition  4007   a  functions to locate the outboard load structure  4003  relative to the upper inboard load structure  4004  and the lower inboard load structure  4005  and also functions as a bearing member therebetween. As a bearing member, the outboard partition  4007   a  distributes force from the corrugations  4003   a  of the outboard load structure  4003  across broader portions of the corrugations  4004   a  of the upper inboard load structure  4004  and the corrugations  4005   a  of the lower inboard load structure  4005  away from the point locations. 
     The inboard partition  4007   b  is similarly arranged between the outboard load structure  4003  and the upper inboard load structure  4004  and the lower inboard load structure  4005 , functions to locate the upper inboard load structure  4004  and the lower inboard load structure  4005 , and functions as a bearing member. In other embodiments, the corrugations  4003   a ,  4004   a ,  4005   a  may directly engage each other, the upper floor subassembly  230 , and/or the lower floor subassembly  218 , for example, with the outboard partition  4007   a  and/or the inboard partition  4007   b  being omitted or discontinuous. 
     Alternatively, the corrugations  4003   a  of the outboard load structure  4003  may be configured relative to the corrugations  4004   a  of the upper inboard load structure  4004  and the corrugations  4005   a  of the lower inboard load structure  4005  in other manners. As shown in  FIG. 44 , corrugations  4403   a  of an outboard load structure  4403  (e.g., member) intersect or cross the corrugations  4004   a  of the upper inboard load structure  4004  at point locations at an upper elevation corresponding to the upper floor subassembly  230  and may also extend upward past the upper inboard load structure  4004 . The corrugations  4403   a  may instead or additionally be configured to cross the corrugations  4005   a  of the lower inboard load structure  4005  at point locations at a lower elevation above the lower floor subassembly  218  (or the member  4218   a  thereof). Alternatively, the corrugations may extend to a lower elevation below the lower floor subassembly  218  (or the member  4218  thereof) and/or extend downward past the lower inboard load structure  4005  (not shown). In another example shown in  FIG. 45 , corrugations  4503   a  of an outboard structure  4503  and corrugations  4504   a ,  4505   a  of upper and lower inboard structures  4504 ,  4505  have substantially coincident patterns, such that the upper and/or lower segments of the corrugations  4503   a  of the outboard structure  4503  intersect (e.g., cross) the corrugations  4504   a ,  4505   a  at line locations (e.g., collinear or otherwise overlapping over straight and/or curved profile of the corrugations  4504   a ,  4505   a ), rather than point locations. 
     In embodiments in which one or more of the outboard load structure  4003 , the upper inboard load structure  4004 , and/or the lower inboard load structure  4005  are configured in other manners (e.g., honeycomb, molded, or foam structures), the outboard load structure  4003  is configured in a similar, suitable manner to vertically overlap and transfer force to the upper inboard load structure  4004  and the lower inboard load structure  4005 . The upper inboard load structure  4004  and the lower inboard load structure  4005  are also configured in a similar, suitable manner to overlap and transfer force to the upper floor subassembly  230  and the lower floor subassembly  218  (or the member  4218   a  thereof), respectively. 
     The outer casing  4006 , in conjunction with the outboard partition  4007   a  and the inboard partition  4008   a , couple the outboard load structure  4003  to the upper inboard load structure  4004  and the lower inboard load structure  4005 , and also maintains substantial alignment therebetween during outboard loading events. The outer casing  4006  may additionally function to couple the sill assembly  102  to the inner floor assembly  110 . 
     Referring again to  FIGS. 40-42B , the outer casing  4006  generally includes an inboard casing structure  4008 , an outboard casing structure  4009 , and an upper casing structure  4010 . The inboard casing structure  4008 , the outboard casing structure  4009 , and the upper casing structure  4010  are continuous members (e.g., stamped aluminum), but may each be made from multiple components, be combined or consolidated into fewer components (e.g., combining the outboard casing structure  4009  and the upper casing structure  4010 ), be made from other manufacturing methods (e.g., extruding), and/or be made from other materials (e.g., steel, composites, etc.). 
     The inboard casing structure  4008  defines a recess  4208   a  in which is received the upper inboard load structure  4004 , the lower inboard load structure  4005 , and the inboard partition  4007   b  coupled thereto. More particularly, the inboard casing structure  4008  includes an inboard segment  4208   b , and an upper segment  4208   c  extending in an outboard direction from an upper end of the inboard segment  4208   b , and a lower segment  4208   d  extending in an outboard direction from a lower end of the inboard segment  4208   b , which cooperatively define the recess  4208   a.    
     The inboard segment  4208   b  of the inboard casing structure  4008  forms the inboard sill region  4202   b  of the sill assembly  102 . The inboard segment  4208   b  protrudes in an inboard direction and is positioned vertically between the upper floor subassembly  230  and the member  4218   a  of the lower floor subassembly  218  and is coupled thereto. More particularly, the inboard segment  4208   b  includes an inboard portion  4208   b ′, an upper portion  4208   b ″ extending outboard (e.g., horizontally) from an upper end of the inboard portion  4208   b ′, and a lower portion  4208   b ″ extending outboard (e.g., horizontally) from a lower end of the inboard portion  4208   b ′. The upper portion  4208   b ″ extends substantially parallel with and adjacent to the upper floor subassembly  230  (e.g., the lower plate  232  thereof) and is coupled thereto (e.g., with elongated fasteners, adhesives, welding, or other suitable method). The lower portion  4208   b ′″ extends substantially parallel with and adjacent to the member  4218   a  of the lower floor subassembly  218  and is coupled thereto (e.g., with elongated fasteners, adhesives, welding, or other suitable method). The inboard portion  4208   b ′ forms an upright wall and may protrude outboard, so as to create a void between the peripheral structure  221  of the intermediate floor subassembly  220 , through which conduits and/or wiring  4203  (e.g., to carry fluid, electricity, and/or data signals) may extend along the fore-aft direction of the vehicle  100 . The sill assembly  102  may be positioned and/or coupled to the inner floor assembly  110  after the wiring  4203  is positioned, such that the wiring  4203  does not require being fished or threaded in the void formed by the inboard portion  4208   b ′ of the inboard segment  4208  of the inboard casing structure  4008 . 
     The inboard casing structure  4008  additionally includes an upper intermediate segment  4208   e  and a lower intermediate segment  4208   f . The upper intermediate segment  4208   e  extends substantially vertically upward from the inboard segment  4208   b  (e.g., from the upper portion  4208   b ″ thereof) to the upper segment  4208   c . The lower intermediate segment  4208   f  extends substantially vertically downward from the inboard segment  4208   b  (e.g., from the lower portion  4208   b ″ thereof) to the lower segment  4208   d . When assembled to the inner floor assembly  110 , the upper intermediate segment  4208   e  and the lower intermediate segment  4208   f  are positioned adjacent to the upper floor subassembly  230  and the member  4218   a  of the lower floor subassembly  218 , respectively. 
     The inboard partition  4007   b  spans the distance between and is coupled to the upper intermediate segment  4208   e  and the lower intermediate segment  4208   f  (e.g., via bonding, spot welding, or other suitable method along vertical interfaces therebetween). The inboard partition  4007   b , thereby, prevents relative movement (e.g., separation and/or compression) of the upper intermediate segment  4208   e  and the lower intermediate segment  4208   f  (e.g., during outboard loading and/or deformation of the upper inboard load structure  4004  and the lower inboard load structure  4005 ). The inboard partition  4007   b , thereby, also aligns the upper inboard load structure  4004  and the lower inboard load structures  4005  to vertically overlap the upper floor subassembly  230  and the member  4218   a  of the lower floor subassembly  218  in the manner described above. 
     The upper segment  4208   c  of the inboard casing structure  4008  extends in an outboard direction (e.g., substantially horizontally) from the upper intermediate segment  4208   e . The upper segment  4208   c  includes an upper flange  4208   g  extending upward (e.g., vertically) therefrom and at which the inboard casing structure  4008  terminates. The upper flange  4208   g  is positioned at an outboard location substantially coincident with an outboard edge of the upper inboard load structure  4004  and the lower inboard load structure  4005 . The upper flange  4208   g  may, as shown, extend above the upper floor subassembly  230 , or to an elevation equal to or below the upper floor subassembly  230 . 
     The lower segment  4208   d  of the inboard casing structure  4008  extends in an outboard direction (e.g., in a convoluted manner) from the lower intermediate segment  4208   f . The lower segment  4208   d  includes a lower flange  4208   h  extending downward (e.g., vertically) therefrom and at which the inboard casing structure  4008  terminates. The lower flange  4208   h  is positioned at an outboard location substantially coincident with the outboard edges of the upper inboard load structure  4004  and the lower inboard load structure  4005 , as well as the upper flange  4208   g . The upper flange  4208   g  may, as shown, extend downward but not below the lower floor subassembly  218  (e.g., due to the convoluted profile of the lower segment  4208   d  of the inboard casing structure  4008 ). The convoluted profile of the lower segment  4208   d , for example, allows for a sill cover  4200   a  to have a curved outer profile protruding inboard from an outboard edge of the sill assembly and above the lower floor subassembly  218 . 
     The outboard partition  4007   a  spans the distance between and is coupled to the upper flange  4208   g  and the lower flange  4208   h  of the inboard segment  4208   b  of the inboard casing structure  4008  (e.g., via bonding, spot welding, or other suitable method along the vertical interfaces therebetween). The outboard partition  4007   a , thereby, prevents relative movement (e.g., separation or compression) of the upper flange  4208   g  and the lower flange  4208   h  (e.g., during outboard loading and/or deformation of the outboard load structure  4003 ). The outboard partition  4007   a , thereby, also aligns the outboard load structure  4003  with the upper inboard load structure  4004  and the lower inboard load structure  4005  in the manner described above. 
     The outboard casing structure  4009  extends outboard and upward from the inboard casing structure  4008  around the outboard load structure  4003 . The outboard casing structure  4009  includes a lower segment  4209   a  extending below the outboard load structure  4003  and an outboard segment  4209   b  extending upward from an outboard end of the outboard load structure  4003 . The outboard casing structure  4009  may additionally include an upper segment  4209   c  extending outboard from an upper end of the outboard segment  4209   b . A lower flange  4209   d  extends downward (e.g., substantially vertically) from an inboard end of the lower segment  4209   a . The lower flange  4209   d  is coupled to a lower end of the outboard partition  4007   a  and to the lower flange  4208   h  of the inboard casing structure  4008  (e.g., via bonding, adhesives, spot welding, or other suitable method), such that the outboard partition  4007   a  is arranged between (e.g., sandwiched) the inboard casing structure  4008  and the outboard casing structure  4009 . An upper flange  4209   e  extends upward from an outboard end of the upper segment  4209   c.    
     The upper casing structure  4010  extends outboard from the inboard casing structure  4008  to the outboard casing structure  4009  above the outboard load structure  4003 . The upper casing structure includes a primary segment  4210   a  extending above the outboard load structure  4003  (e.g., substantially horizontally), and includes an inboard flange  4210   b  and an outboard flange  4210   c  extending upward (e.g., substantially vertically) from inboard and outboard ends of the primary segment  4210   a . The inboard flange  4210   b  is coupled to an upper end of the outboard partition  4007   a  and the upper flange  4208   g  of the inboard casing structure  4008  (e.g., via bonding, adhesives, spot welding, or other suitable method), such that the outboard partition  4007   a  is arranged between (e.g., sandwiched) the inboard casing structure  4008  and the upper casing structure  4010 . By also being coupled to the lower flange  4208   h  of the inboard casing structure  4008  and the lower flange  4209   d  of the outboard casing structure  4009 , the outboard partition  4007   a , thereby, prevents relative movement (e.g., separation or compression) of the upper casing structure  4010  (e.g., the inboard flange  4210   b  thereof) and the outboard casing structure  4009  (e.g., the lower flange  4209   f  thereof) during outboard loading and/or deformation of the various components of the sill assembly  102 . The outboard flange  4210   c  of the upper casing structure  4010  is also coupled to the upper flange  4209   g  of the outboard casing structure  4009 . 
     The sill assembly  102  additionally includes, or is configured to releasably receive, a beam structure  4011  in the outboard sill region  4202   c . The beam structure  4011  is configured to function as a load spreader that distributes forces from outboard loading across the outboard load structure  4003 . The beam structure  4011  has greater inboard compressive strength and greater bending stiffness about a vertical axis (e.g., in adjacent locations and/or elongated regions extending a majority or substantial majority of the fore-aft length of the sill  102 ), such that the beam structure spreads load in a fore-aft direction and inboard to the outboard load structure  4003 . The beam structure  4011  thereby spreads load across the outboard load structure  4003 , which deforms more fully in an inboard direction (e.g., collapsible width) along the fore-aft direction (e.g., length) earlier than the beam structure  4011 . The beam structure  4011  is positioned to vertically overlap the outboard load structure  4003  (e.g., at an elevation at least partially between the upper segments  4003   c  and the lower segments  4003   d  of the corrugations  4003   a ), and is in close proximity thereto (e.g., being in contact with the outboard casing structure  4009 ). 
     The beam structure  4011  may, for example, be an extruded steel member (e.g., boron steel) that extends in a fore-aft direction a substantial majority of a length of the sill assembly  102 . The beam structure  4011  may additionally include internal webs  4011   a , which stiffen the beam structure  4011 . The beam structure  4011  may, however, be configured in other manners, such as comprising multiple components coupled to each other, or being formed from different materials. Furthermore, while the beam structure  4011  is depicted as having a rectangular cross-sectional shape, it may instead have another profile, such as a curved or angled outer profile to account for different contours of the sill cover  4200   a . In a still further example, as shown in  FIG. 46 , the sill assembly  102  may instead include multiple beam members  4611  (e.g., a forward beam member and a rearward beam member) that are included in one or more movable door assemblies (not labeled). The beam members  4611  may, for example, be releasably coupled to another rigid member of the sill assembly  102 , such as a latch base  4611   a  of a cinching latch assembly. This allows for the doors to open and close and also function as a load spreader, in conjunction with the latch base  4611   a  releasably coupled thereto, to distribute forces from outboard loading across the outboard load structure  4003 .

Metadata:
Filing Date: 20170920
Publication Date: 20190604
Grant Date: 20190604
Priority Date: 20160920
Inventors: DEQUINE, DUSTIN L.
WOODS, MATTHEW I.
MAKOWSKI, KEVIN P.
RISTOSKI, TONI
Assignee: APPLE INC
CPC Classifications: [{"code": "B62D25/2036", "inventive": true, "first": false, "tree": "[]"}, {"code": "B62D29/005", "inventive": false, "first": false, "tree": "[]"}, {"code": "B62D29/008", "inventive": false, "first": false, "tree": "[]"}, {"code": "B62D29/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "B60Y2306/01", "inventive": false, "first": false, "tree": "[]"}, {"code": "B62D25/025", "inventive": true, "first": false, "tree": "[]"}, {"code": "B62D25/2036", "inventive": true, "first": false, "tree": "[]"}, {"code": "B60K2001/0438", "inventive": false, "first": false, "tree": "[]"}, {"code": "B60K1/04", "inventive": true, "first": true, "tree": "[]"}, {"code": "B62D25/20", "inventive": true, "first": true, "tree": "[]"}, {"code": "B60K1/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "B62D29/005", "inventive": true, "first": false, "tree": "[]"}, {"code": "B60Y2306/01", "inventive": false, "first": false, "tree": "[]"}, {"code": "B60K2001/0438", "inventive": false, "first": false, "tree": "[]"}, {"code": "B60K1/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "B60K2001/0438", "inventive": false, "first": false, "tree": "[]"}, {"code": "B62D29/005", "inventive": true, "first": false, "tree": "[]"}, {"code": "B62D25/20", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 66673230