TECHNICAL FIELD

[0001] The present disclosure relates to rocker assemblies and more specifically to rocker inserts for vehicle rocker structures.

BACKGROUND

[0002] Vehicle frames and body structures are designed to support the vehicle and undergo and absorb certain levels of impact forces, such as to prevent distances of inboard intrusion into the vehicle in accordance with various regulatory and legal requirements. Side impacts to a vehicle are commonly tested with side pole impact testing, which direct significant side impact forces to the vehicle. Vehicle frames primarily absorb these side impacts at rocker sections that run longitudinally between the front and rear wheels along the lower outboard portions of the vehicle frame.

[0003] With the incorporation of battery trays in electric and hybrid electric vehicles in the lateral inboard area between opposing rocker sections, it is desirable for the side impact forces to be directed away from the battery tray and towards a vehicle floor cross member. For example, it is generally known to increase stiffness of a vehicle rocker assembly such as by adding a rocker insert within the vehicle rocker assembly.

SUMMARY

[0004] The present disclosure provides a rocker component of a rocker assembly for a vehicle. The rocker component includes a hollow beam that has a metal sheet forming a closed cross-sectional shape that extends continuously along a length of the hollow beam, such as to form a tubular shape that surrounds a hollow interior. The hollow beam includes a wall portion that borders the closed cross-sectional shape, or, in other words, the wall portion is a section of the metal sheet that forms a wall or wall portion of hollow beam. The wall portion is generally planar or otherwise disposed in a single plane. The hollow beam provides a plurality of beads that are disposed at the wall portion of the hollow beam and are spaced along the length of the hollow beam. The beads are defined as laterally extending formations in the metal sheet that function to improve the lateral compressive strength of the hollow beam. [0005] According to one aspect of the disclosure a rocker component is provided for a vehicle rocker assembly. The rocker component includes a hollow beam having a metal sheet that forms a closed cross-sectional shape continuously along a length of the hollow beam. The hollow beam includes a wall portion that borders the closed cross-sectional shape and is disposed in a single plane. A plurality of beads are disposed at the wall portion of the hollow beam and are spaced along the length of the hollow beam.

[0006] According to another aspect of the disclosure, a vehicle rocker assembly is provided that includes a sill inner having a sill wall portion, an upper wall portion, a lower wall portion, an upper flange portion, and a lower flange portion. The vehicle rocker assembly also includes a sill outer comprising a sill wall portion, an upper wall portion, a lower wall portion, an upper flange portion, and a lower flange portion. A rocker component of the vehicle rocker assembly includes a hollow beam having a metal sheet that forms a closed cross-sectional shape continuously along a length of the hollow beam. The hollow beam includes a wall portion bordering the closed cross-sectional shape and disposed in a single plane. Additionally, the hollow beam includes a plurality of beads that are disposed at the wall portion of the hollow beam and spaced along the length of the hollow beam.

[0007] Implementations of the disclosure may include one or more of the following optional features. In some examples, each of the plurality of beads protrude inward into the closed cross-sectional shape of the hollow beam.

[0008] In some examples, each of the plurality of beads are elongated in the single plane in a direction not parallel to the length of the hollow beam.

[0009] In yet other examples, each of the plurality of beads are elongated in a direction perpendicular to the length of the hollow beam.

[0010] In yet other examples, each of the plurality of beads are elongated in a direction between 30-90 degrees relative to the length of the hollow beam.

[0011] In yet other examples, a first set of the plurality of beads are elongated in a first direction, and wherein a second set of the plurality of beads are elongated in a second direction.

[0012] In yet other examples, the plane is disposed generally horizontal relative to the vehicle.

[0013] In yet other examples, the hollow beam comprises a second wall portion bordering the closed cross-sectional shape and disposed in a second plane. Additionally, in some examples, the hollow beam comprises a second plurality of beads disposed in the second wall portion. Moreover, in some examples, the second wall portion is disposed in planar parallel alignment with the wall portion.

[0014] Additionally, in some examples, the second wall portion is dispersed on an opposite side of the closed cross-sectional shape of the hollow beam from the wall portion.

[0015] In some examples, the plurality of beads each comprise a width and a length, and the length is longer than the width.

[0016] In some examples, the plurality of beads each comprise a length that is greater than half the width of the beam.

[0017] In some examples, the plurality of beads each comprise a length that is less than the width of the beam.

[0018] In another example, a rocker component of a rocker assembly for a vehicle including a hollow beam having a metal sheet that forms a closed cross-sectional shape continuously along a length of the hollow beam. The hollow beam includes a wall portion bordering the closed cross-sectional shape and disposed in a single plane. Additionally, the hollow beam includes a plurality of beads disposed in the wall portion of the hollow beam and spaced along the length of the hollow beam.

[0019] The details of one or more implementations of the disclosure are set forth in the accompanying drawings and the description below. Other aspects, advantages, purposes, and features will be apparent upon review of the following specification in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] FIG. 1 is a perspective view of a vehicle schematically showing a rocker assembly and a battery tray enclosure;

[0021] FIG. 2A is a side elevation view of a vehicle schematically showing a rocker assembly and other structural components;

[0022] FIG. 2B is a cross-sectional view of the rocker assembly taken along the line indicated in FIG. 2A;

[0023] FIG. 3 is a perspective view of a vehicle rocker component shown in FIG. 2B; [0024] FIG. 3A is a top elevation view of the vehicle rocker component shown in FIG. 3;

[0025] FIG. 3B is a cross sectional view of the vehicle rocker component shown in FIG. [0026] FIG. 4 is a perspective view of another example of a vehicle rocker component;

[0027] FIG. 4A is a bottom view of the vehicle rocker component shown in FIG. 4;

[0028] FIG. 4B is a cross sectional view of the vehicle rocker component shown in FIG.

4;

[0029] FIG. 5 is a perspective view of another example of a vehicle rocker component;

[0030] FIG. 5 A is a bottom view of the vehicle rocker component shown in FIG. 5;

[0031] FIG. 5B is a cross sectional view of the vehicle rocker component shown in FIG.

5;

[0032] FIG. 6 is a perspective view of another example of a vehicle rocker component;

[0033] FIG. 6A is a bottom view of the vehicle rocker component shown in FIG. 6;

[0034] FIG. 6B is a cross sectional view of the vehicle rocker component shown in FIG.

6;

[0035] FIG. 7 is a perspective view of another example of a vehicle rocker component;

[0036] FIG. 7A is a bottom view of the vehicle rocker component shown in FIG. 7;

[0037] FIG. 7B is a cross sectional view of the vehicle rocker component shown in FIG.

7;

[0038] FIG. 8 is a perspective view of another example of a vehicle rocker component;

[0039] FIG. 8 A is a bottom view of the vehicle rocker component shown in FIG. 8;

[0040] FIG. 8B is a cross sectional view of the vehicle rocker component shown in FIG.

8;

[0041] FIG. 9 is a perspective view of another example of a vehicle rocker component;

[0042] FIG. 9A is a bottom view of the vehicle rocker component shown in FIG. 9;

[0043] FIG. 9B is a cross sectional view of the vehicle rocker component shown in FIG.

9;

[0044] FIG. 10 is a perspective view of another example of a vehicle rocker component;

[0045] FIG. 10A is a bottom view of the vehicle rocker component shown in FIG. 10;

[0046] FIG. 10B is a cross sectional view of the vehicle rocker component shown in

FIG. 10;

[0047] FIG. 11 is a perspective view of another example of a vehicle rocker component;

[0048] FIG. 11A is a bottom view of the vehicle rocker component shown in FIG. 11;

[0049] FIG. 1 IB is a cross sectional view of the vehicle rocker component shown in

FIG. 11;

[0050] FIG. 12 is a perspective view of another example of a vehicle rocker component; [0051] FIG. 12A is a bottom view of the vehicle rocker component shown in FIG. 12;

[0052] FIG. 12B is a cross sectional view of the vehicle rocker component shown in

FIG. 12;

[0053] FIG. 13 is a perspective view of another example of a vehicle rocker component;

[0054] FIG. 13A is a bottom view of the vehicle rocker component shown in FIG. 13;

[0055] FIG. 13B is a cross sectional view of the vehicle rocker component shown in

FIG. 13;

[0056] FIG. 14 is a perspective view of another example of a vehicle rocker component;

[0057] FIG. 14A is a bottom view of the vehicle rocker component shown in FIG. 14;

[0058] FIG. 14B is a cross sectional view of the vehicle rocker component shown in

FIG. 14;

[0059] FIG. 15 is a perspective view of another example of a vehicle rocker component;

[0060] FIG. 15A is a bottom view of the vehicle rocker component shown in FIG. 15;

[0061] FIG. 15B is a cross sectional view of the vehicle rocker component shown in

FIG. 15;

[0062] FIG. 16 is a perspective view of another example of a vehicle rocker component;

[0063] FIG. 16A is a bottom view of the vehicle rocker component shown in FIG. 16;

[0064] FIG. 16B is a cross sectional view of the vehicle rocker component shown in

FIG.16;

[0065] FIG. 17 is a perspective view of another example of a vehicle rocker component;

[0066] FIG. 17A is a bottom view of the vehicle rocker component shown in FIG. 17;

[0067] FIG. 17B is a cross sectional view of the vehicle rocker component shown in

FIG. 17;

[0068] FIG. 18 is a perspective view of another example of a vehicle rocker component;

[0069] FIG. 18A is a bottom view of the vehicle rocker component shown in FIG. 18;

[0070] FIG. 18B is a cross sectional view of the vehicle rocker component shown in

FIG. 18;

[0071] FIG. 19 is a perspective view of another example of a vehicle rocker component;

[0072] FIG. 19A is a bottom view of the vehicle rocker component shown in FIG. 19; and

[0073] FIG. 19B is a cross sectional view of the vehicle rocker component shown in FIG. 19.

[0074] Like reference numerals indicate like parts throughout the drawings. DETAILED DESCRIPTION

[0075] Referring now to the drawings and the illustrative embodiments depicted therein, a rocker assembly is provided for a vehicle 100, such as for a body structure or frame 102 as shown in FIGS. 1 and 2A. The vehicle frame 102 and associated components may have various designs and configurations, such as for different styles and types of vehicles. As shown for example FIGS. 1 and 2A, the vehicle frame has various structural components that support the body of the vehicle and protect passengers, engine components, and sensitive electronics from damage when undergoing collisions. In some examples, the vehicle may be operated by a propulsion system that uses a battery, such as a battery or battery modules that may be supported in a battery tray 104, such as shown in FIG. 1. The battery tray 104 may generally be located between the axles and below the floor to distribute the battery weight in the vehicle.

[0076] As shown in FIGS. 1-2B, the vehicle rocker component 10 includes a sill panel or panels, such as a sill inner panel 12 and sill outer panel 14 that attach together around an interior area 16, where the terms “inner” and “outer” are made in reference to inboard or inward facing and outboard or outward facing directions on the vehicle, such as oriented in FIG. 1. As shown in FIG. 2B, the example of the vehicle rocker assembly 10 is provided with a reinforcement insert disposed in the interior area 16 to form a multi -tubular rocker structure. As shown in FIG. 1, the rocker assembly 10 is disposed alongside an outer section of the battery tray 104, where the floor cross-member may be attached to the vehicle rocker assembly 10 so as to span laterally over the battery tray 104. Accordingly, the vehicle component in additional implementations may also or alternatively be provided as a battery tray frame component, such as a longitudinally oriented side wall section of the battery tray. [0077] When designing the vehicle rocker assembly with a rocker insert disclosed herein, the outer dimensions of the vehicle rocker assembly may be reduced and the overall weight of the vehicle rocker assembly may be reduced while meeting the required impact and loading conditions. The rocker insert may span a partial section of the vehicle rocker assembly or the entire length of the rocker assembly, such as to extend beyond the rocker assembly into and to also reinforce an adjacent component. The rocker insert disclosed herein may comprise the entire vehicle component or may be joined to additional reinforcements or parts of the vehicle component, such as at desired sections of the vehicle component. Further, in some examples the rocker assembly may be embodied as a subassembly or as part of a corresponding vehicle component, such as a structural component or a battery tray component and as such may be designed to undergo various impact forces and to support and sustain different loading conditions.

[0078] Moreover, the rocker insert disclosed herein may be formed with one or more pieces of sheet material, such as by roll forming a metal sheet, to provide the structure with a relatively high strength (for shear and axial loading) and low weight in comparison to common rocker panels, such as to allow the sill panels of the corresponding vehicle component to use less material, occupy a smaller packaging space, and have greater flexibility in the outer shape design. Other forming processes, including but not limited to stamping, have also been contemplated. The cross-sectional shape of different examples of the vehicle component and rocker insert may include various shapes and thicknesses for the desired application of the vehicle component.

[0079] Unless specified to the contrary, it is generally understood that additional implementations of the rocker component may have an opposite orientation from the examples shown and described, such as where the sill panels identified as an inner panel may be used as the outer panel and the sill panels identified as an outer panel may be used as the inner panel. The cross-sectional shape of the inner and outer panels may vary along the rocker, such as, for example, by flaring outward at the ends.

[0080] Referring now to the vehicle rocker assembly 10 shown in FIG. 2B, a first sill panel 12 and a second sill panel 14 are attached together to surround a hollow interior space 16 between the sill panels 12, 14. The vehicle rocker assembly 10 shown in FIG. 2B is embodied as a vehicle rocker component. Accordingly, the first sill panel 12 may be referred to as a sill inner panel of a rocker component. The first sill panel 12 has an upper flange 18 and a lower flange 20 that extend along respective upper and lower edges of the inner panel. The first sill panel 12 protrudes inboard from the upper and lower flanges 18, 20 to form outward facing concave structures. The second sill panel 14, which may be referred to as a sill outer panel of a rocker component, has a C-shaped cross section with flanges 22, 24, which may similarly be referred to as an upper flange 22 and a lower flange 24. The upper flanges 18, 22 and the lower flanges 20, 24 of the inner and outer sill panels 12, 14 are attached together, such as via welding, with the concave structures facing each other. The upper and lower flanges 18, 20, 22, 24 of each of the sill panels 12, 14 shown in FIG. 2B extend longitudinally, continuously along the edges of the rocker component; however, it is contemplated that the flanges may be trimmed away in select areas to facilitate frame attachment or to reduce weight. [0081] As further shown in FIG. 2B, the inner and outer sill panels 12, 14 are joined together to define a hollow interior space 16 between the sill panels 12, 14. The upper and lower flanges 18, 20, 22, 24 are substantially planar and oriented in a generally vertical configuration, such as to mate in generally continuous contact along the length of the component. The upper and lower flanges 18, 20, 22, 24 may be j oined together via welding, and preferably spot welding, although it is conceivable that alternative welding methods or joining means may be used in addition or in the alternative to spot welding in different implementations of a rocker component, such as adhesive or fasteners or the like.

[0082] The first sill panel 12, or inner panel of the vehicle rocker assembly 10, has an inner wall 26 that is substantially planar. The inner wall 26 integrally interconnects with a comer transition to an upper wall 28 and a lower wall 30 at the respective upper and lower ends. The comer transitions are approximately 90 degrees between the inner wall 26 and the upper and lower walls 28, 30. Also, the comer transitions are defined by the longitudinal bends to a sheet material that forms the first sill panel 12, such as a metal sheet (e.g., an advanced high strength steel sheet or aluminum sheet). Similarly, the upper and lower walls 28, 30 each have a comer transition of approximately 90 degrees to the upper flange 18 and the lower flange 20, respectively. The comer transitions are also defined by longitudinal bends in the sheet material of the first sill panel 12, such as formed by a roll form process. As also shown in FIG. 2B, the upper and lower flanges 18, 20 are substantially planar and oriented in parallel alignment with the planar extent of the inner wall 26. The upper and lower walls 28, 30 of the first sill panel 12 are also substantially planar and, as shown in FIG. 2B, are substantially parallel to each other, although in additional examples they may be slightly angled from each other. The comer transitions may also have an angular transition greater or less than shown in FIG. 2B, such as approximately between 40 and 120 degrees, between 70 and 100 degrees, between 80 and 95 degrees, or between 82 and 92 degrees.

[0083] As also shown in FIG. 2B, the second sill panel 14 or outer panel of the vehicle rocker assembly 10 has an outer wall 32 that is substantially planar and integrally interconnects with an upper wall 34 and a lower wall 36 at its respective upper and lower ends. The comer transitions of approximately 80 degrees between the outer wall 32 and the upper and lower walls 34, 36 are defined by longitudinal bends to a sheet material that forms the second sill panel 14. The sheet material may be the same or different from the first sill panel 12 and may include a metal sheet, such as an advanced high strength steel sheet or aluminum sheet. Similarly, the upper wall 34 also has a comer transition to the upper flange 22 and the lower wall 36 has a comer transition to the lower flange 24, which are each also defined by longitudinal bends in the sheet material of the second sill panel 14. Again, the comer transitions between the upper and lower walls 34, 36 and the upper and lower flanges 22, 24 and the outer wall 32 may have an angular transition greater or less than shown in FIG. 2B, such as approximately between 40 and 120 degrees, between 70 and 100 degrees, between 80 and 95 degrees, or between 82 and 92 degrees.

[0084] As shown in FIG. 2B, the upper and lower flanges 22, 24 are substantially planar and oriented in parallel alignment with the planar extent of the outer wall 32. The upper and lower walls 34, 36 of the second sill panel 14 are also substantially planar, but are slightly angled from being orthogonal to the outer wall 32 and flanges 22, 24. With the flanges 18, 20, 22, 24 of the panels 12, 14 attached together, the walls thereof define a substantially hexagonal cross-sectional shape; however, it is appreciated that additional examples of the rocker insert may have various alternative cross-sectional shapes (e.g., a substantially rectangular shape) and different wall configurations for the corresponding vehicle design (e.g., portions of the inner or outer walls that are not vertically oriented). It is also contemplated that in other examples the outer sill and the inner sill may each include a different configuration including but not limited to the outer sill having an inward or outward protruding stiffening rib portion configured to provide additional stiffness and side impact support.

[0085] As further shown in FIG. 2B, the rocker assembly 10 includes a rocker insert 40 disposed within the elongated hollow interior 16. The rocker insert 40 includes a hollow beam 43 defined by an upper wall 42, a lower wall 44, and at least one side wall 46 extending between the upper wall 42 and the lower wall 44 to surround a hollow interior 50. In other words, the hollow beam 43 may be defined by a tubular member 48 that is at least partially defined by the upper wall 42, the lower wall 44, and the side wall 46 surround a hollow interior 50. In some examples, the side wall of the rocker insert is coupled with the sill inner or the sill outer to support the rocker insert in the elongated hollow interior. In other examples, the side walls of the rocker insert are coupled to the sill inner and the sill outer to support the rocker insert in the rocker assembly.

[0086] As shown in FIG. 2B, the rocker insert 40 includes a flange 41 that is coupled to the upper wall 42 and the lower wall 44 and the sill inner 12 or the sill outer 14 to support the rocker insert 40 in the elongated hollow interior 16. In the example shown in FIG. 2B, the rocker insert 40 includes top and bottom flanges 41 that are provided by brackets spaced along the length of the rocker component. In some examples, the flange or brackets are disposed only on the upper wall. In other examples, the one or more flanges are disposed only on the lower wall. The flanges may also be disposed on one or both of the side walls. Moreover, having one or more flanges disposed on any of the above in combination has also been contemplated.

[0087] The upper wall 42 and the lower wall 44 are generally rectangular in shape along the length of the rocker insert 40 and the opposing sidewalls 46 are also generally rectangular in shape. As shown in FIGS. 3-3B, the opposing side walls 46 have a vertical dimension or height that is less than the horizontal dimension or depth of the upper and the lower walls 42, 44. Additionally, the upper wall 42 and the lower wall 44 have the same horizontal dimension or depth and the sidewalls 46 have the same vertical dimension or height. As further shown in FIGS. 2B-3B the outboard side wall 46 has a recessed portion 75 or channel formed along the length of the insert. The recessed portion 75 is illustrated as being generally equidistant between the upper wall 42 and the lower wall 44, however, various other side wall locations for a recess are contemplated. Moreover, the recessed portion may be curved between the upper and lower wall or may be a more angular recessed portion.

[0088] Referring now to the example shown in FIGS. 3-3B, the upper wall 42 and the lower wall 44 include a plurality of beads disposed at or in the wall portion of the hollow beam 43 and spaced along the length of the hollow beam 43. The plurality of beads 60 may be disposed on any surface of the upper or lower wall 42, 44. By being formed into the metal sheet of the rocker insert 14, the plurality of beads 60 are disposed on the top surface 52 and the bottom surface 54 of each the upper wall 42 and the lower wall 44. In other examples, the plurality of beads may be disposed on the top surface or the bottom surface of the upper or lower wall. Additionally, it has been contemplated that in additional examples that one or more surface of one or more of the opposing side walls may also include the plurality of beads.

[0089] In some examples, such as shown in FIGS. 3-3B, the plurality of beads 60 each protrude inward into the closed cross-sectional shape of the hollow beam 43. Each of the beads 60 includes a ridge 62 which is the greatest height of the bead and a furrow 64 which is the lowest height of the bead 60. In other words, the ridge 62 is the initial area of inward deformation to the metal sheet, which generally circumscribes the periphery of each bead. The furrow 64 is the area of the greatest degree of inward deformation to the metal sheet, at the most inward part of each bead. As shown in FIGS. 3-3B, the ridge 62 of the bead 60 is at the same height as the remaining or surrounding top surface 52 or bottom surface 55 of the upper or lower wall 42, 44. In other words, the height of the ridge 62 may be generally equal to the height of the top surface 52 while the furrow extends into the hollow interior. [0090] Referring still to the example shown in FIGS. 3-3B, the plurality of beads 60 each comprise a width and a length, and the length is longer than the width. In some examples, the plurality of beads 60 each comprise a length that is greater than half the width of the hollow beam 43. In other examples, wherein the plurality of beads 60 each comprise a length that is less than the width of the beam. In one example, the plurality of beads are generally oval shaped such that the portions of the beads 60 which extends adjacent the first and second side walls of the tubular member are rounded. However, various other bead shapes have been contemplated such as rectangular, circular, triangular and the like.

[0091] In the example shown in FIGS. 3-3B, the plurality of beads 60 has a furrow 64 oriented to extend in a lateral vehicle direction. The lateral vehicle direction generally extends across the width dimension of the vehicle. In contrast, the longitudinal vehicle direction generally extends along the length dimension of the vehicle. In some examples, an apex 66 of the furrow 64 may be disposed in a generally horizontal plane. The furrows 64 of the plurality of beads 60 are configured to be oriented to generally align with anticipated lateral impacts to the side of a vehicle, so as to provide increased stiffness to the corresponding portion of the upper or lower wall 44 of the rocker insert 40. Moreover, the furrow 64 of the plurality of beads 60 extends at least partially between the sill wall portions of the sill inner 12 and the sill outer 14. In some examples the plurality of beads 60 may be across an entire surface or may be disposed on only a portion of the surface. The ridges 62 and the furrows 64 may be of any shape and side as desired, including but not limited to the furrow 64 being a v-shape or a u-shape. It is also contemplated that the ridge 62 and the furrow 64 may be the same shape or may be different shapes than one another, if desired. Moreover, it is contemplated that the ridges 62 and/or the furrows 64 may be a single repeating shape, may be alternating shapes, or any pattern as desired.

[0092] Moreover, it is contemplated that the plurality of beads 60 may include additional ridges 62 between the ridge 62 and the furrow 64 which may provide additional strength to the tubular member.

[0093] In some examples, the plurality of beads 60 includes furrows 64 having the same height continuously along the length of the hollow beam 43. However, it is also contemplated that a single bead 60 may have a different furrow depth than another of the plurality of beads, if desired. In some examples, the furrow 64 has a width of approximately 0.5-1.5 mm. In other examples the furrow 64 has a width of approximately 0.8-1.3 mm. In yet another example, the furrow 64 has a width of approximately 0.9- 1.1 mm. In one example, the furrow 64 has a width of approximately 0.9 mm. In another example, the furrow 64 has a width of approximately 1.1mm. However, various other furrow 64 widths have been contemplated. In one example, the beads 60 are formed a distance away from the side wall thus increasing the strength of the tubular member 40.

[0094] In one example, the plurality of beads 60 are formed in a sheet of material prior to the material being formed into the tubular member 40. In one example, the sheet of material begins in a coil form and is fed into a stamping or other operation which forms the beads 60. Once the beads 60 are formed, the sheet of material is fed to a roll-former where the remainder of the tubular member is formed. Additionally, it is contemplated that the beads 60 may be formed during or after the roll forming process, if desired.

[0095] Referring now to the example shown in FIGS. 4-4B, the rocker insert 140 shown is similar to the rocker insert 40 as described above with respect to the example shown in FIGS. 3-3B including but not limited to the rocker insert 140 including the upper wall 142, the lower wall 144, the side wall 146 extending between the upper wall 142 and the lower wall 144, and the plurality of beads 160. However, in the example shown in FIGS. 4-4B, the plurality of beads 160 is only disposed on the bottom surface 153 of the lower wall 144. Moreover, in the example shown, the upper wall 142 is a smooth surface such that the upper wall 142 does not include beads 160.

[0096] Referring now to the example shown in FIGS. 5-5B, the rocker insert 240 shown is similar to the rocker insert 40 as described above with respect to the example shown in FIGS. 3-3B including but not limited to the rocker insert 240 including the upper wall 242, the lower wall 244, the side wall 246 extending between the upper wall 242 and the lower wall 244, and the plurality of beads 260. Additionally, the example in FIG. 5-5B also includes at least one flange. The flange 243 in the example shown in FIG. 5-5B extends from the bottom surface of the lower wall 244 approximately perpendicularly before turning and extending parallel to the bottom surface of the lower wall 244. Moreover, the flange 243 includes another section perpendicular to the bottom surface of the lower wall 244 and coupled to the parallel section forming a second hollow interior. In one example, the flange 243 extends the length of the rocker insert 340, however, it is contemplated that a plurality of flanges 243 of different sizes and/or shapes may be disposed on the lower wall 244. In one example, best illustrated in FIG. 5B, one of the perpendicular sections of the flange 243 may extend to the side wall 246 of the rocker insert 340 to provide a welding surface to secure the flange to the rocker insert. Moreover, in the example shown, the flange 243 is slightly off-center from the central width of the bottom surface such that the flange is disposed closer to one side wall 246 than the other side wall 246. However, a central flange or other configuration of flange have also been contemplated.

[0097] Referring now to the example shown in FIGS. 6-6B, the rocker insert 340 shown is similar to the rocker insert 40 as described above with respect to the example shown in FIGS. 3-3B including but not limited to the rocker insert 340 including the upper wall 342, the lower wall 344, the side wall 346 extending between the upper wall 342 and the lower wall 344, and the plurality of beads 360. However, in the rocker insert illustrated in FIG. 6- 6B, the rocker insert 340 also includes a center wall 371 disposed within the hollow interior. The center wall 371 as shown is generally disposed equidistant between the upper wall 342 and the lower wall 344. However, other distances have been contemplated. Additionally, the center wall 371 includes a plurality of beads 60 disposed about the length, similar to the upper and lower walls 342, 344. It is contemplated that one or more of the upper wall 342, the lower wall 344, and the center wall 371 include the plurality of beads 60 in any combination.

[0098] Referring nor to the example shown in FIGS. 7-7B, the rocker insert 440 shown is similar to the rocker insert 40 as described above with respect to the example shown in FIGS. 3-3B including but not limited to the rocker insert 440 including the upper wall 442, the lower wall 444, the side wall 446 extending between the upper wall 442 and the lower wall 444, and the plurality of beads 460. However, in the example illustrated in FIGS. 7- 7B, the upper wall 442 and the lower wall 444 extend at an angle towards one another and are not parallel as shown in the example in FIGS. 3-3B. Additionally, to accommodate the non-parallel extension, one of the first or second side wall 446 has a greater height than the other side wall 446. Moreover, in the example shown, the side wall 446 having the smaller height includes the recessed portion 475, which in the example shown is a rounded recessed portion. However, various other configurations have been contemplated including but not limited to the recessed portion 475 being angular and/or the recessed portion 475 being disposed on the side wall 446 which has a greater height. Moreover, while it is illustrated in FIG. 7B that the angle is approximately 20-40 degrees, however various other angles of extension have been contemplated including but not limited to 5-85 degrees, 10-75 degrees, 15-65 degrees, and the like.

[0099] Referring now to the example shown in FIGS. 8-8B, the rocker insert 540 shown is similar to the rocker insert 40 as described above with respect to the example shown in FIGS. 3-3B but not limited to the rocker insert 540 including the upper wall 542, the lower wall 544, the side wall 546 extending between the upper wall 542 and the lower wall 544, and the plurality of beads 560. However, in the example shown in FIGS. 8-8B the recessed portion 575 extends away from the center of the hollow interior instead of towards the center of the hollow interior as shown in previous examples. Moreover, the recessed portion 575 forms a point in a generally arrow-like shape which extends from the upper wall 542 and the lower wall 544. It is contemplated that the recessed portion 575 may be of another shape, including but not limited to a more rounded shape.

[00100] Referring now to the example shown in FIGS. 9-9B, the rocker insert 640 shown is similar to the rocker insert 40 as described above with respect to the example shown in FIGS. 3-3B but not limited to the rocker insert 640 including the upper wall 642, the lower wall 644, the side wall 646 extending between the upper wall 642 and the lower wall 644, and the plurality of beads 660. However, in the example shown in FIGS. 9-9B, the rocker insert does not include a recessed portion 675 at all. Moreover, the first and second side walls 646 extend parallel between the upper wall 642 and the lower wall 644.

[00101] Referring now to the example shown in FIGS. 10-10B, the rocker insert 740 shown is similar to the rocker insert 40 as described above with respect to the example shown in FIGS. 3-3B but not limited to the rocker insert 740 including the upper wall 742, the lower wall 744, the side wall 746 extending between the upper wall 742 and the lower wall 744, and the plurality of beads 760. However, in the example shown in FIGS. 10-10B, each of the plurality of beads are elongated in the single plane in a direction not parallel to the length of the hollow beam 43. In one example, each of the plurality of beads are elongated in a direction between 30-90 degrees relative to the length of the hollow beam 43. In one example, the plurality of beads disposed in the upper wall 742 and the lower wall 744 are elongated at the same angle. In other examples, the plurality of beads 760 disposed in the upper wall 742 and the lower wall 744 are elongated at different angles.

[00102] Referring now to the example shown in FIGS. 11-1 IB, the rocker insert 840 shown is similar to the rocker insert 40 as described above with respect to the example shown in FIGS. 3-3B but not limited to the rocker insert 840 including the upper wall 842, the lower wall 844, the side wall 846 extending between the upper wall 842 and the lower wall 844, and the plurality of beads 860. However, in the example shown in FIGS. 11-1 IB, each of the plurality of beads 860 are elongated in the single plane in a direction not parallel to the length of the hollow beam 43. In one example, each of the plurality of beads 860 are elongated in a direction between 30-90 degrees relative to the length of the hollow beam 43. In one example, the plurality of beads 860 disposed in the upper wall 842 and the lower wall 844 are elongated at the same angle. In other examples, the plurality of beads disposed in the upper wall and the lower wall are elongated at different angles.

[00103] Referring now to the example shown in FIGS. 12-12B, the rocker insert 940 shown is similar to the rocker insert 40 as described above with respect to the example shown in FIGS. 3-3B but not limited to the rocker insert 940 including the upper wall 942, the lower wall 944, the side wall 946 extending between the upper wall 942 and the lower wall 944, and the plurality of beads 960. However, in the example shown in FIGS. 12-12B, the plurality of beads 960 are again elongated in a direction not parallel to the length of the hollow beam 43. Additionally, in the example shown the plurality of beads 960 extend in a first rotational direction along a portion of the length of the tubular member and then extend in an opposite rotational direction along the remainder of the length of the hollow beam 43. In one example, some of the plurality of beads 960 are elongated in a direction between 30- 90 degrees relative to the length of the hollow beam 43 and other of the plurality of beads 960 are elongated in a direction between -30 — 90 degrees relative to the length of the hollow beam 43. In one example, the plurality of beads 960 disposed in the upper wall 942 and the lower wall 944 are disposed in the same pattern on the upper wall 942 and the lower wall 944. In other examples, the plurality of beads 960 disposed in the upper wall 942 and the lower wall 944 at different angles or patterns from one another.

[00104] Referring now to the example shown in FIGS. 13-13B, the rocker insert 1040 shown is similar to the rocker insert 40 as described above with respect to the example shown in FIGS. 3-3B but not limited to the rocker insert 1040 including the upper wall 1042, the lower wall 1044, the side wall 1046 extending between the upper wall 1042 and the lower wall 1044, and the plurality of beads 1060. However, in the example shown in FIGS. 13- 13B, in the example shown the plurality of beads 1060 extend in a first rotational direction and then extend in an opposite rotational direction. In one example, the plurality of beads 1060 extending in the first rotational direction and the plurality of beads 1060 extending in the second rotational direction are disposed in a repeating pattern along the length of the hollow beam 43. In one example, some of the plurality of beads 1060 are elongated in a direction between 30-90 degrees relative to the length of the hollow beam 43 and other of the plurality of beads are elongated in a direction between -30 — 90 degrees relative to the length of the hollow beam 43. In one example, the plurality of beads 1060 disposed in the upper wall 1042 and the lower wall 1044 are disposed in the same pattern on the upper wall 1042 and the lower wall 1044. In other examples, the plurality of beads 1060 disposed in the upper wall 1042 and the lower wall 1044 at different angles or patterns from one another. [00105] Referring now to the example shown in FIGS. 14-14B, the rocker insert 1140 shown is similar to the rocker insert 40 as described above with respect to the example shown in FIGS. 3-3B but not limited to the rocker insert 1140 including the upper wall 1142, the lower wall 1144, the side wall 1146 extending between the upper wall 1142 and the lower wall 1144, and the plurality of beads 1160. However, in the example shown in FIGS. 14- 14B the plurality of beads 1160 are rectangular in shape. In the example shown, the upper wall 1142 and the lower wall 1144 includes a repeating pattern of rectangular shaped beads. However, it is also contemplated that more or less beads 1160 may be present on the upper wall 1142. Moreover, it is contemplated that the beads 1160 may be placed a consistent distance from one another, as illustrated, or the beads 1160 may be disposed otherwise on the upper wall 1142. Additionally, while the example shown in FIG. 14 includes beads 1160 on both the upper wall 1142 and the bottom wall 1144, it is contemplated that only one of the surfaces may include beads 1160.

[00106] Referring now to the example shown in FIGS. 15-15B, the rocker insert 1240 shown is similar to the rocker insert 40 as described above with respect to the example shown in FIGS. 3-3B but not limited to the rocker insert 1240 including the upper wall 1242, the lower wall 1244, the side wall 1246 extending between the upper wall 1242 and the lower wall 1244, and the plurality of beads 1260. However, in the example shown in FIGS. 15- 15B the plurality of beads 1260 are triangular in shape. In the example shown, the upper wall 1242 and the lower wall 1244 includes a repeating pattern of triangular shaped beads 1260. However, it is also contemplated that more or less beads 1260 may be present on the upper wall 1244. Moreover, it is contemplated that the beads 1260 may be placed a consistent distance from one another, as illustrated, or the beads 1260 may be disposed otherwise on the upper wall 1242. Additionally, while the example shown in FIG. 15 includes beads on both the upper wall 1242 and the lower wall 1244, it is contemplated that only one of the surfaces may include beads 1260. [00107] Referring now to the example shown in FIGS. 16-16B, the rocker insert 1340 shown is similar to the rocker insert 40 as described above with respect to the example shown in FIGS. 3-3B but not limited to the rocker insert 1340 including the upper wall 1342, the lower wall 1344, the side wall 1346 extending between the upper wall 1342 and the lower wall 1344, and the plurality of beads 1360. However, in the example shown in FIGS. 16- 16B the plurality of beads 1360 are X-shaped. In the example shown, the upper wall 1342 and the lower wall 1344 includes a repeating pattern of X-shaped shaped beads. However, it is also contemplated that more or less beads 1360 may be present on the upper wall 1342. Moreover, it is contemplated that the beads 1360 may be placed a consistent distance from one another, as illustrated, or the beads 1360 may be disposed otherwise on the upper wall 1342. Additionally, while the example shown in FIG. 16 includes beads 1360 on both the upper wall 1342 and the lower wall 1344, it is contemplated that only one of the surfaces may include beads 1360.

[00108] Referring now to the example shown in FIGS. 17-17B, the rocker insert 1440 shown is similar to the rocker insert 40 as described above with respect to the example shown in FIGS. 3-3B but not limited to the rocker insert 1440 including the upper wall 1442, the lower wall 1444, the side wall 1446 extending between the upper wall 1442 and the lower wall 1444, and the plurality of beads 1460. However, in the example shown in FIGS. 17- 17B the plurality of beads 1460 are half circle or rainbow shaped. In the example shown, the upper wall 1442 and the lower wall 1444 includes a repeating pattern of half-circle or rainbow shaped beads. However, it is also contemplated that more or less beads 1460 may be present on the upper wall 1442. Moreover, it is contemplated that the beads 1460 may be placed a consistent distance from one another, as illustrated, or the beads 1460 may be disposed otherwise on the upper wall 1442. Additionally, while the example shown in FIG. 17 includes beads on both the upper wall 1442 and the lower wall 1444, it is contemplated that only one of the surfaces may include beads 1460.

[00109] Referring now to the example shown in FIGS. 18-18B, the rocker insert 1540 shown is similar to the rocker insert 40 as described above with respect to the example shown in FIGS. 3-3B but not limited to the rocker insert 1540 including the upper wall 1542, the lower wall 1544, the side wall 1546 extending between the upper wall 1542 and the lower wall 1544, and the plurality of beads 1560. However, in the example shown in FIGS. 18- 18B, the plurality of beads 1560 include a central reinforcement protrusion 91 disposed generally central within the beads 1560. It is also contemplated that more reinforcement protrusions 91 may be disposed on other location within the beads 1560. Moreover it is contemplated that the reinforcement protrusion 91 may be disposed on another location within the bead 1560. Additionally, it is contemplated that some of the plurality beads 1560 may not include the reinforcement protrusion 91, if desired.

[00110] Referring now to the example shown in FIGS. 19-19B, the rocker insert 1640 shown is similar to the rocker insert 40 as described above with respect to the example shown in FIGS. 3-3B but not limited to the rocker insert 1640 including the upper wall 1642, the lower wall 1644, the side wall 1646 extending between the upper wall 1642 and the lower wall 1644, and the plurality of beads 1660. Additionally, the plurality of beads 1660 are disposed at an angle relatively to the length of the rocker insert 1640. However, in the example shown in FIGS. 19-19B, the plurality of beads 1660 extend outwardly from one or more of the upper wall 1642 or the lower wall 1644. The plurality of beads 1660 may have any of the features described about with respect to the beads 60, including but not limited to the orientation, size, shape, and location of the beads 60.

[00111] In some examples such as the examples described above, having a rocker insert 40, 140 with a plurality of beads 60 reduces mass by up to approximately 42% while also providing approximately a 22% reduction in overall intrusion providing a light-weight, yet strong rocker insert 40, 140.

[00112] The inner and outer sill panels 12, 14 and rocker insert may be roll-formed from an advanced high-strength steel with a tensile strength above 1,000 MPA, such as approximately 1,500 MPa. The metal sheet used to roll form the center wall or membrane of rocker insert may be approximately 1.2 mm in thickness, such as between 1.0 mm and 1.6 mm. Also, the steel sheet used for the rocker insert and panels of the vehicle component may be galvanized, so as to have a zinc coating that protects against corrosion. In some examples, however, the steel sheet of the rocker insert 40 may not be galvanized, and in other examples the steel sheets that form the vehicle component may not be galvanized. In further examples, the metal sheet that forms the rocker insert is an aluminum sheet. The length of the inner sill panel 12 is substantially equal to a length of the outer sill panel 14. In additional implementations, the length of the inner sill panel 12 may be shorter than the length of the hollow interior space of the corresponding component, such as between 40% and 100%, between 30% and 90%, or between 30% and 60% of the length of the rocker insert. The sill inner 12 and sill outer 14 may be coupled by welding, using fasteners, adhesive, or another coupling method. The coupling of the rocker insert 40 and one of the sill inner 12 and the sill outer 14 may provide additional strength to the vehicle rocker assembly.

[00113] It is also contemplated that the internal reinforcements of the disclosed vehicle rocker assembly may be incorporated in other types of structural beams, such as in frames and structures of automotive and marine vehicles, buildings, storage tanks, furniture, and the like. With respect to vehicle applications, the vehicle component disclosed herein may be incorporated with various applications of different structural components. The vehicle component may be designed to support and sustain different loading conditions, such as for supporting certain horizontal spans or axial loading conditions. Also, the vehicle component may be designed to undergo various impact forces, such as for the illustrated rocker assemblies, pillar structures, and the like. The cross-sectional geometry, material type selections, and material thickness within the cross-sectional profile of the vehicle component may be configured for such a particular use and the desired loading and performance characteristics, such as the weight, load capacity the beam, force deflection performance, and impact performance of the vehicle component.

[00114] For purposes of this disclosure, the articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements in the preceding descriptions. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional implementations that also incorporate the recited features. Furthermore, the terms “first,” “second,” and the like, as used herein do not denote any order, quantity, or importance, but rather are used to denote element from another.

[00115] Numbers, percentages, ratios, or other values stated herein are intended to include that value, and also other values that are “about” or “approximately” the stated value, as would be appreciated by one of ordinary skill in the art encompassed by implementations of the present disclosure. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result. For example, the terms “approximately,” “about,” and “substantially” may refer to an amount that is within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of a stated amount. [00116] Further, it should be understood that any directions or reference frames in the preceding description are merely relative directions or movements. For example, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” “inboard,” “outboard” and derivatives thereof shall relate to the orientation shown in FIG. 1. However, it is to be understood that various alternative orientations may be provided, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in this specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

[00117] Changes and modifications in the specifically described embodiments may be carried out without departing from the principles of the present invention, which is intended to be limited only by the scope of the appended claims as interpreted according to the principles of patent law. The disclosure has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present disclosure are possible in light of the above teachings, and the disclosure may be practiced otherwise than as specifically described.