CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

[0001] This application claims the benefit of and priority to U.S. Provisional Application No. 62/424,965, filed November 21, 2016, the entire disclosure of which is hereby incorporated by reference herein.

BACKGROUND

[0002] The present application relates generally to structural beams for vehicles, such as door beams or bumper beams.

SUMMARY

[0003] One embodiment relates to a beam for a vehicle. The beam includes a base, a first side flange, and a second side flange. The base includes a facing wall, a first side wall, and a second side wall. The first and second side walls each extend downwardly from the facing wall. Each of the side flanges includes a foot extending outwardly therefrom, an arm extending upwardly from an end of the foot, and a shelf extending outwardly from an end of the arm toward the first and second side walls, respectively. The shelf is oriented generally parallel to the foot and is disposed below the facing wall of the base.

[0004] Another embodiment relates to a beam for a vehicle. The beam includes a base, a first side flange, and a second side flange. The base includes a facing wall, a first side wall, and a second side wall. The first and second side walls each extend downwardly from the facing wall and outwardly away from each other. The first side flange extends outwardly from the first side wall. The second side flange extends outwardly from the second side wall. Each of the first and second side flanges comprises a foot extending outwardly therefrom, an arm extending upwardly from an end of the foot, and a shelf extending inwardly from an end of the arm toward the first and second side walls, respectively. The shelf is oriented generally parallel to the foot and the facing wall, and is disposed at a height that is below the facing wall of the base. [0005] Another embodiment relates to a beam for a vehicle. The beam includes a base, a first side flange, and a second side flange. The base includes a facing wall, a first side wall, and a second side wall. The first and second side walls each extend downwardly from the facing wall. The first side flange extends outwardly from the first side wall. The second side flange extends outwardly from the second side wall. Each of the first and second side flanges includes a plurality of steps extending upwardly toward the facing wall and inwardly toward the first and second side walls, respectively.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] FIG. 1 is a perspective sectional view of a conventional structural beam for a vehicle, according to the prior art.

[0007] FIG. 2 is a front view of a door frame including a beam according to an exemplary embodiment.

[0008] FIG. 3 is a front view of a front portion of a vehicle including a beam according to another exemplary embodiment.

[0009] FIG. 4 is a partial perspective view of a beam for a vehicle according to an exemplary embodiment.

[0010] FIG. 5 is a partial perspective view of a beam for a vehicle according to another exemplary embodiment.

[0011] FIG. 6 is a partial perspective view of a beam for a vehicle according to another exemplary embodiment.

[0012] FIG. 7 is a partial perspective view of a beam for a vehicle according to another exemplary embodiment.

[0013] FIGS. 8-9 illustrate the beam of FIG. 4 experiencing a load at first and second stages of deformation according to an exemplary embodiment.

[0014] FIGS. 10-11 illustrate the beam of FIG. 5 experiencing a load at first and second stages of deformation according to another exemplary embodiment. [0015] FIGS. 12-13 illustrate the beam of FIG. 6 experiencing a load at first and second stages of deformation according to another exemplary embodiment.

[0016] FIGS. 14-15 illustrate the beam of FIG. 7 experiencing a load at first and second stages of deformation according to another exemplary embodiment.

[0017] FIG. 16 is a graph of simulated load/displacement plots for various beam structures according to an exemplary embodiment.

[0018] FIG. 17 is a graph of actual load/displacement plots for various beam structures according to another exemplary embodiment.

DETAILED DESCRIPTION

[0019] Generally speaking, most conventional structural beams for vehicles have a basic "hat" or "tube" cross-sectional shape. For example, FIG. 1 illustrates a conventional structural beam for a vehicle having a basic hat-shape, according to the prior art. Some structural beams for vehicles are made from steel by a roll-forming process, which can be costly and time consuming to implement. In addition, these conventional steel beams can add significant weight to a vehicle. Other structural beams are made from a composite material, but these composite beams can have limited ductility/energy absorption, as compared to steel.

[0020] Referring generally to the Figures, disclosed herein are structural beams for a vehicle made from a composite material (e.g., glass fiber and resin, glass roving and resin, glass mat and resin, carbon fiber and resin, carbon roving and resin, carbon mat and resin, etc.) and including a unique structural shape to provide sufficient ductile deformation when subjected to a load, so as to match or exceed the deformation characteristics of steel and conventional composite beams. In this manner, the composite beams weigh much less than conventional steel beams, but have good ductility to provide similar or better energy absorption, as compared to conventional steel beams. In addition, the structural shape of the beams provides for improved ductility/energy absorption than conventional composite beams. According to various exemplary embodiments, the structural beams disclosed herein can be configured for use as a vehicle door beam (see, for example, FIG. 1 A), a vehicle bumper beam (see, for example, FIG. IB), or for use as another type of structural beam on a vehicle where crash protection is desired.

[0021] According to various exemplary embodiments, the beams can have any one of, or a combination of, the structural configurations shown in the Figures. Each of the various beam structures disclosed herein includes a side flange having a structure that can be selectively modified to control the peak load and displacement of the beam when subjected to a load. For example, each of the side flanges includes a structural shape that defines one or more deformation zones (e.g., transition edges, levels, tiers, regions, localized crush zones, ridgelines, etc.) located at different heights or levels along the beam for absorbing a load at various stages of deformation. By controlling the configuration of the deformation zones on the side flanges of the beam, the peak load and displacement of the beam can be controlled and tailored for a particular application.

[0022] According to an exemplary embodiment, the various beam structures disclosed herein are made from a composite material, such as an epoxy resin and/or an unsaturated polyester and a glass fiber material or carbon fiber (e.g., fiberglass, woven roving, glass mat, carbon mat, etc.). According to other exemplary embodiments, the various beams can be made from another rigid or semi-rigid composite material or combinations of materials. Production methods of prepreg and fiber-reinforced composite material according to the present application can employ, for example, a pultrusion method. For example, the fiber- reinforced composite material can be obtained as follows: the reinforcing fiber may be continuously passed through a resin bath (e.g., a resin bath filled with the composition according to the present application) to thereby impregnate the composition into the reinforcing fiber; then, as required, the resultant may be passed through a squeeze die to thereby form a prepreg; thereafter, for example, the resultant can be cured while being passed through a heated mold and subjected to continuous pultrusion by a pulling machine, to thereby obtain the fiber-reinforced composite material. The obtained fiber-reinforced composite material may further be subjected to a heat treatment (e.g., post-baking) using an oven or the like. The pultrusion process described above may use a die that can be changed so as to change the resulting beam structure (e.g., the side flange structure, etc.), depending on the particular application of the beam. In this manner, the various beams disclosed herein can be easily reconfigured for a particular vehicle application, as compared to conventional roll-formed steel beams.

[0023] Referring to FIG. 2, a beam 100a (e.g., a door beam, a structural beam, a vehicle beam, etc.) is shown coupled to a door frame 110a for a vehicle according to an exemplary embodiment. The beam 100a can, advantageously, act as a structural support for the door frame 110a when, for example, the door frame 110a undergoes a crash event on the vehicle, such as a side impact event with another vehicle or object. The beam 100a is made from a composite material and has a structural shape that can advantageously absorb at least a portion of the load experienced by the door frame 110a during a crash event. In this manner, the beam 100a can help to protect occupant(s) of the vehicle and can reduce the overall weight of the vehicle.

[0024] Similarly, referring to FIG. 3, a beam 100b (e.g., a bumper beam, a structural beam, a vehicle beam, etc.) is shown coupled to a front portion 110b of a vehicle according to another exemplary embodiment. The beam 100b can, advantageously, act as a structural support for the front portion 110b of the vehicle, such as behind a bumper fascia, when, for example, the vehicle undergoes a crash event, such as a frontal impact event with another vehicle or object. The beam 100b is made from a composite material and has a structural shape that can advantageously absorb at least a portion of the load experienced by the front portion 110b of the vehicle during a frontal crash event. In this manner, the beam 100b can help to protect occupant(s) of the vehicle and can reduce the overall weight of the vehicle.

[0025] Referring to FIGS. 4-7, three different beam structures are shown according to various exemplary embodiments. The beams of FIGS. 4-7 can be configured for use as a structural beam for a vehicle door, such as door frame 110a shown in FIG. 2, or as a structural beam for a bumper of a vehicle, such as front portion 110b of the vehicle shown in FIG. 3. According to other exemplary embodiments, the beams can be configured for use as a structural beam for a rear bumper of a vehicle or for use as another type of structural beam for a vehicle where crash protection is desired.

[0026] Referring to FIG. 4, a partial perspective view of a beam 200 is shown according to an exemplary embodiment. As shown in the embodiment of FIG. 4, the beam 200 is a generally elongated member. The beam 200 includes a base collectively defined by a facing wall 201 (e.g., impact surface, facing surface, etc.), a first side wall 203 (e.g., first leg, first side, right side, first side surface, etc.), and a second side wall 205 (e.g., second leg, second side, left side, second side surface, etc.). The first side wall 203 and the second side wall 205 each extend downwardly from the facing wall 201. According to an exemplary embodiment, the first side wall 203 and the second side wall 205 are each oriented at an angle smaller than 90 degrees (e.g., about 85 degrees) relative to the facing wall 201, such that the first side wall 203 and the second side wall 205 extend outwardly away from each other (i.e., the first side wall 203 and the second side wall 205 are not parallel to each other). This is particularly advantageous to allow for displacement of the first and second side walls 203, 205 outwardly away from the center of the beam 200 when experiencing a load, the details of which are discussed in the paragraphs that follow. According to another exemplary embodiment, the first side wall 203 and the second side wall 205 are each oriented at the same angle relative to the facing wall 201. As shown in FIG. 4, the facing wall 201 is generally planar. According to other exemplary embodiments, the facing wall 201 can be contoured (e.g., curved, etc.). The facing wall 201, the first side wall 203, and the second side wall 205 cooperatively define a first deformation zone (e.g., first level, first tier, etc.) of the beam 200.

[0027] As shown in FIG. 4, the transitions between the facing wall 201 and the first side wall 203 and between the facing wall 201 and the second side wall 205, are defined by a first pair of transition edges 202, 204 (e.g., primary transition edges, impact corners, etc.) of the beam 200. The first pair transition edges 202, 204 are configured to act as a first contact point or first deformation zone for the beam 200 when the beam experiences a load at the facing wall 201. For example, referring to FIG. 8, when the beam 200 experiences a force or load "L" at the facing wall 201 (shown with beam 200 oriented in an upright direction and the load "L" facing in a downward direction for ease of reference, although other orientations of the beam 200 are contemplated), the outwardly extending first and second side walls 203, 205 will be displaced in an outward direction away from the center of the beam 200 (i.e., away from the center of the facing wall 201). This displacement direction of the first and second side walls 203, 205 will cause the facing wall 201 to bow in a downward direction, thereby causing the load "L" to be substantially supported at the first pair of transition edges 202, 204 during a first stage of deformation/loading shown in FIG. 8 (i.e., the transitions or corners between the facing wall 201 and the first side wall 203 and between the facing wall 201 and the second side wall 205).

[0028] The beam 200 is configured such that the facing wall 201 faces outwardly toward a load when the beam is coupled to a vehicle. According to an exemplary embodiment, the beam 200 can be oriented such that the facing wall 201 faces toward an outer side of a vehicle. For example, the beam 200 can be coupled to a vehicle door frame, such as door frame 110a in FIG. 2, such that the facing wall 201 is positioned within the door frame adjacent to or abutting against an inner surface of an outer door skin (not shown). In this way, when the door frame 110a experiences a load (e.g., during a side-impact event, etc.), the facing wall 201 and/or the first pair of transition edges 202, 204 will be the first portion of the beam 200 to absorb/experience the load. Similarly, the beam 200 can be coupled to a vehicle bumper (e.g., front or rear bumper, etc.), such as front portion 110b of a vehicle in FIG. 3, such that the facing wall 201 is positioned on the front portion of the vehicle adjacent to or abutting against an inner surface of a bumper fascia (not shown). In this manner, when the front portion 110b experiences a load (e.g., during a frontal impact event, etc.), the facing wall 201 and/or the first pair of transition edges 202, 204 will be the first portion of the beam 200 to absorb/experience the load.

[0029] Still referring to FIG. 4, the beam 200 further includes a pair of side flanges extending outwardly away from the first side wall 203 and the second side wall 205, respectively. A first side flange 208 (e.g., a right side flange, etc.) is collectively defined by a first foot 207 (e.g., shoulder, member, etc.), a first arm 211 (e.g., upright wall, etc.), and a first shelf 215 (e.g., ledge, finger, etc.). Similarly, a second side flange 210 (e.g., a left side flange, etc.) is collectively defined by a second foot 209, a second arm 213, and a second shelf 217.

[0030] As shown in FIG. 4, the first foot 207 is disposed at an end of the first side wall 203. The first foot 207 extends outwardly away from the first side wall 203 in a direction that is generally parallel to the facing wall 201. The first arm 21 1 extends upwardly from an end of the first foot 207. According to an exemplary embodiment, the first arm 211 is oriented generally perpendicular to the first foot 207. The first arm 211 extends upward a distance that is less than half the height of the first side wall 203, according to the embodiment of FIG. 4. The first shelf 215 extends inwardly from an end of the first arm 211 in a direction that is generally parallel to the first foot 207 (i.e., the first shelf 215 extends back across toward the first side wall 203). The first shelf 215 can be spaced apart from the first side wall 203 to define a gap therebetween to, advantageously, allow for displacement of the first side flange 208 when experiencing a load. The first foot 207, the first arm 211, and the first shelf 215 cooperatively define part of a second deformation zone of the beam 200.

[0031] Similarly, referring to FIG. 4, the second side flange 210 is defined by the second foot 209, the second arm 213, and the second shelf 217. The second foot 209 is disposed at an end of the second side wall 205. The second foot 209 extends outwardly away from the second side wall 205 in a direction that is generally parallel to the facing wall 201. The second arm 213 extends upwardly from an outer end of the second foot 209. According to an exemplary embodiment, the second arm 213 is oriented generally perpendicular to the second foot 209. The second arm 213 extends upward a distance that is less than half the height of the second side wall 205, according to the embodiment of FIG. 4. The second shelf 217 extends inwardly from an end of the second arm 213 in a direction that is generally parallel to the second foot 209 (i.e., the second shelf 217 extends back across toward the second side wall 205). The second shelf 217 can be spaced apart from the second side wall 205 to define a gap therebetween to, advantageously, allow for displacement of the second side flange 210 when experiencing a load. According to the exemplary embodiment shown, the second shelf 217 is disposed at substantially the same height as the first shelf 215. The second foot 209, the second arm 213, and the second shelf 217 cooperatively define part of the second deformation zone of the beam 200. Thus, the second deformation zone of the beam 200 is collectively defined by the first and second side flanges 208, 210 (i.e., first and second feet 207, 209; first and second arms 211, 213; and first and second shelves 215, 217,

respectively).

[0032] As shown in FIG. 4, the transitions or corners between the first arm 211 and the first shelf 215, and between the second arm 213 and the second shelf 217, are defined by a second pair of transition edges 212, 214 (e.g., secondary transition edges, secondary impact corners, etc.) of the beam 200. The second pair of transition edges 212, 214 are configured to act as a secondary contact point or second deformation zone for the beam 200 when the beam experiences a load at the facing wall 201. For example, as shown in FIGS. 8-9, when the beam 200 experiences a force or load "L" (e.g., a distributed load, etc.) at the facing wall 201, the outwardly extending first and second side walls 203, 205 will be displaced in an outward direction away from the center of the beam 200 (i.e., away from the center of the facing wall 201). This displacement direction of the first and second side walls 203, 205 will cause the facing wall 201 to bow in a downward direction, thereby causing the load to be substantially supported at the first pair of transition edges 202, 204 during a first stage of deformation shown in FIG. 8 (i.e., the transitions or corners between the facing wall 201 and the first side wall 203 and between the facing wall 201 and the second side wall 205). As the first and second side walls 203, 205 are displaced outwardly, the first and second side flanges 208, 210 will simultaneously rotate inwardly toward the center of the beam 200 during a second stage of deformation shown in FIG. 9, such that the first and second shelves 215, 217 are oriented in a downward direction, and the second pair of transition edges 212, 214 define an uppermost portion of each of the first and second side flanges 208, 210. Thus, as shown in FIG. 9, the load will be substantially supported at both the first pair of transition edges 202, 204 and the second pair of transition edges 212, 214.

[0033] In other words, when the beam 200 is subjected to a load at an outer surface of the facing wall 201, the first deformation zone (i.e., the first pair of transition edges 202, 204) will substantially support/absorb the load during a first stage of deformation. The first deformation zone will continue to support the load until the first deformation zone is elastically/plastically deformed or displaced to a level or height along the beam 200 that the first and/or second side flanges (i.e., the second deformation zone) take over and begin to substantially support the load during a second stage of deformation. The first and second side flanges 208, 210 will then, advantageously, help to support/absorb the load with the first pair of transition edges 202, 204 until the entire beam fails. In this manner, the beam 200 can provide for similar or better energy absorption as steel, while providing for much better ductility/energy absorption than conventional composite beams. The other beam structures disclosed in FIGS. 5-7 behave in a similar manner, and the above discussion applies equally to these structures (see, for example, FIGS. 10-15). [0034] Referring to FIG. 5, where like reference numerals refer to identical components between Figures (e.g., facing wall 201 in FIG. 4 is identical to facing wall 301 in FIG. 5), a partial perspective view of a beam 300 is shown according to another exemplary

embodiment. The beam 300 is identical to the beam 200 of FIG. 4, except for the

configuration of the side flanges. For example, as shown in FIG. 5, the first arm 311 extends upwardly from the first foot 307 a distance that is more than half the height of the first side wall 303, but less than the height of the facing wall 301 (i.e., the first shelf 315 and the second shelf 317 are located offset from the facing wall 301). Likewise, the second arm 313 extends upwardly from the second foot 309 substantially the same distance as the first arm 311. In this manner, the first shelf 315 and the second shelf 317 are each disposed at a height that is higher than the respective first and second shelves 215, 217 of the beam 200, but are each positioned lower than the facing wall 301. Thus, the second deformation zone or the second pair of transition edges 312, 314 is disposed at a height that is closer to the first deformation zone or the first pair of transition edges 302, 304 of the beam 300. In this way, the beam 300 can withstand a greater peak load than the beam 200, but can exhibit less displacement than the beam 200, the details of which are discussed in the paragraphs that follow.

[0035] For example, referring to FIGS. 10-11, when the beam 300 experiences a force or load "L" (e.g., a distributed load, etc.) at the facing wall 301, the outwardly extending first and second side walls 303, 305 will be displaced in an outward direction away from the center of the beam 300 (i.e., away from the center of the facing wall 301). This displacement direction of the first and second side walls 303, 305 will cause the facing wall 301 to bow in a downward direction, thereby causing the load to be substantially supported at the first pair of transition edges 302, 304 during a first stage of deformation shown in FIG. 10 (i.e., the transitions or corners between the facing wall 301 and the first side wall 303 and between the facing wall 301 and the second side wall 305). As the first and second side walls 303, 305 are displaced outwardly during a second stage of deformation shown in FIG. 11, the first and second side flanges 308, 310 will simultaneously rotate inwardly toward the center of the beam 300, such that the first and second shelves 315, 317 are oriented in a downward direction, and the second pair of transition edges 312, 314 define an uppermost portion of each of the first and second side flanges 308, 310. Thus, as shown in FIG. 11, the load "L" will be substantially supported at both the first pair of transition edges 302, 304 and the second pair of transition edges 312, 314 (i.e., the first and second deformation zones). In this manner, the beam 300 can provide for similar or better energy absorption as steel, and can exceed the ductility/energy absorption of conventional composite beams.

[0036] Referring to FIG. 6, where like reference numerals refer to identical components between Figures (e.g., facing wall 201 in FIG. 4 is identical to facing wall 401 in FIG. 6), a partial perspective view of a beam 400 is shown according to another exemplary

embodiment. The beam 400 is identical to the beam 200 of FIG. 4 and the beam 300 of FIG.

5, except for the configuration of the side flanges. For example, as shown in FIG. 6, the first arm 411 extends upwardly from the first foot 407 a distance that is less than half the height of the first side wall 403, similar to the beam 200 of FIG. 4. However, each of the first and second side flanges includes a plurality of shelves (e.g., steps, levels, etc.) that are defined by a plurality of transition edges or corners (e.g., at least two pairs of transition edges, at least three pairs of transition edges, etc.) for each of the side flanges 408, 410. As shown in FIG.

6, each of the first and second side flanges 408, 410 includes a plurality of steps that extend generally upwardly toward the facing wall 401 and inwardly toward the first and second side walls 403, 405, respectively.

[0037] For example, the first side flange 408 further includes a second arm 419 extending upwardly from the first shelf 415, a second shelf extending inwardly from the second arm 419 (i.e., back across toward the first side wall 403), a third arm 427 extending upwardly from the second shelf 423, and a third shelf 431 extending inwardly from the third arm 427 (i.e., back across toward the first side wall 403). According to the exemplary embodiment shown, the first arm 411, the second arm 419, and the third arm 427 each extend

approximately the same distance and in substantially the same direction (i.e., generally vertically or perpendicular to the first foot 407). Likewise, the first shelf 415, the second shelf 423, and the third shelf 431 each extend approximately the same distance and in substantially the same direction (i.e., generally horizontally or perpendicular to the respective arms). The third shelf 431 is spaced apart from the first side wall 403 to define a gap therebetween to, advantageously, allow for displacement of the first side flange 408 when experiencing a load. The third shelf 431 is disposed at a height that is more than half the height of the first side wall 403, but is less than the height of the facing wall 401 (i.e., the third shelf 431 is located offset from the facing wall 401). The first arm 411, the first shelf 415, the second arm 419, the second shelf 423, the third arm 427, and the third shelf 431 collectively define part of a second deformation zone of the beam 400.

[0038] Similarly, the second side flange 410 further includes a fourth arm 413 extending upwardly from the second foot 409, a fourth shelf 417 extending inwardly from the fourth arm 413 (i.e., back across toward the second side wall 405), a fifth arm 421 extending upwardly from the fourth shelf 417, a fifth shelf 425 extending inwardly from the fifth arm 421 (i.e., back across toward the second side wall 405), a sixth arm 429 extending upwardly from the fifth shelf 425, and a sixth shelf 433 extending inwardly from the sixth arm 429 (i.e., back across toward the second side wall 405). According to the exemplary embodiment shown, the fourth arm 413, the fifth arm 421, and the sixth arm 429 each extend

approximately the same distance and in substantially the same direction (i.e., generally vertically or perpendicular to the second foot 409). Likewise, the fourth shelf 417, the fifth shelf 425, and the sixth shelf 433 each extend approximately the same distance and in substantially the same direction (i.e., generally horizontally or perpendicular to the respective arms). The sixth shelf 433 is spaced apart from the second side wall 405 to define a gap therebetween to, advantageously, allow for displacement of the second side flange 410 when experiencing a load. The sixth shelf 433 is disposed at a height that is more than half the height of the second side wall 405, but is less than the height of the facing wall 401 (i.e., the sixth shelf 433 is located offset from the facing wall 401). The fourth arm 413, the fourth shelf 417, the fifth arm 421, the fifth shelf 425, the sixth arm 429, and the sixth shelf 433 collectively define part of the second deformation zone of the beam 400. Thus, the second deformation zone is collectively defined by the first and second side flanges 408, 410.

[0039] As shown in FIG. 6, the transitions or corners between the first arm 411 and the first shelf 415, and between the fourth arm 413 and the fourth shelf 417, are defined by a second pair of transition edges 412, 414 of the beam 400. Similarly, the transitions or corners between the second arm 419 and the second shelf 423, and between the fifth arm 421 and the fifth shelf 425, are defined by a third pair of transition edges 420, 422. And the transitions or corners between the third arm 427 and the third shelf 431 and between the sixth arm 429 and the sixth shelf 433 are defined by a fourth pair of transition edges 428, 430. The second, third, and fourth pairs of transition edges cooperate together to act as a secondary contact point or second deformation zone for the beam 400 when the beam experiences a load at the facing wall 401.

[0040] For example, referring to FIGS. 12-13, when the beam 400 experiences a force or load "L" (e.g., a distributed load, etc.) at the facing wall 401, the outwardly extending first and second side walls 403, 405 will be displaced in an outward direction away from the center of the beam 400 (i.e., away from the center of the facing wall 401). This displacement direction of the first and second side walls 403, 405 will cause the facing wall 401 to bow in a downward direction, thereby causing the load to be substantially supported at the first pair of transition edges 402, 404 during a first stage of deformation shown in FIG. 12 (i.e., the transitions or corners between the facing wall 401 and the first side wall 403 and between the facing wall 401 and the second side wall 405). As the first and second side walls 403, 405 are displaced outwardly during a second stage of deformation shown in FIG. 13, the first and second side flanges 408, 410 will simultaneously rotate inwardly toward the center of the beam 400, such that the first and fourth shelves 415, 417 are oriented in a downward direction, and the second pair of transition edges 412, 414, the third pair of transition edges 420, 422, and the fourth pair of transition edges 428, 430 define an uppermost portion of each of the first and second side flanges 408, 410. Thus, as shown in FIG. 13, the load "L" will be substantially supported at both the first pair of transition edges 402, 404 and the second, third, and fourth pairs of transition edges (i.e., the first and second deformation zones). In this manner, the beam 400 can provide for similar or better energy absorption as steel, and can exceed the ductility/energy absorption of conventional composite beams.

[0041] Referring to FIG. 7, where like reference numerals refer to identical components between Figures (e.g., facing wall 201 in FIG. 2 is identical to facing wall 501 in FIG. 7), a partial perspective view of a beam 500 is shown according to another exemplary

embodiment. The beam 500 is identical to the beam 200 of FIG. 4, except for the

configuration of the side flanges. For example, as shown in FIG. 7, each of the side flanges 508, 510 includes an end portion (i.e., first end portion 519 and second end portion 520) extending downwardly from an end of the respective first and second shelves 515, 517. Each of the first and second end portions 519, 520 is oriented substantially perpendicular to the first and second shelves 515, 517, respectively. The first and second end portions 519, 520 are spaced apart from the first and second side walls 503, 505 in a lateral direction, and are spaced from the first and second feet 507, 509 in a longitudinal direction. The transitions or corners between the first shelf 515 and the first end portion 519, and between the second shelf 517 and the second end portion 520 are defined by a third pair of transition edges 516, 518, respectively. As shown in FIG. 7, the third pair of transition edges 516, 518 are disposed inward or between the second pair of transition edges 512, 514. The second pair of transition edges 512, 514 define the second deformation zone for the beam 500.

[0042] Referring to FIGS. 14-15, when the beam 500 experiences a force or load "L" (e.g., a distributed load, etc.) at the facing wall 501, the outwardly extending first and second side walls 503, 505 will be displaced in an outward direction away from the center of the beam

500 (i.e., away from the center of the facing wall 501). This displacement direction of the first and second side walls 503, 505 will cause the facing wall 501 to bow in a downward direction, thereby causing the load to be substantially supported at the first pair of transition edges 502, 504 during a first stage of deformation shown in FIG. 6G (i.e., the transitions or corners between the facing wall 501 and the first side wall 503 and between the facing wall

501 and the second side wall 505). As the first and second side walls 503, 505 are displaced outwardly during a second stage of deformation shown in FIG. 15, the first and second side flanges 508, 510 will simultaneously rotate inwardly toward the center of the beam 500, such that the first and second shelves 515, 517 are oriented in a downward direction, and the second pair of transition edges 512, 514 define an uppermost portion of each of the first and second side flanges 508, 510. Thus, as shown in FIG. 15, the load "L" will be substantially supported at both the first pair of transition edges 502, 504 and the second pair of transition edges 512, 514 (i.e., the first and second deformation zones). In this manner, the beam 500 can provide for similar or better energy absorption as steel, and can exceed the

ductility/energy absorption of conventional composite beams.

[0043] In the various exemplary embodiments of FIGS. 4-7, the transition edges or corners between the various portions of the beams 200, 300, 400, 500 (e.g., between the facing wall 201 and the first side wall 203 of beam 200, etc.) are shown having a filleted edge. According to other exemplary embodiments, the transition edges or corners between the various portions of the beams can have a chamfered edge or a combination of chamfered and filleted edges.

[0044] Referring to FIG. 16, a computer simulated load/displacement graph is shown for the various beam structures disclosed herein according to an exemplary embodiment. Each of the beams 200, 300, 400, and 500 were subjected to a simulated load to produce the plots shown in FIG. 16. A conventional "hat-shaped" composite beam was also subjected to a simulated load for comparison with the beam structures of the present application (i.e., labeled as "simple hat shape"). In the example shown in FIG. 16, the simulated beams 200, 300, 400, and 500 were made from glass fiber and epoxy resin, and each included a glass fiber content (Vf) of 69%. The total energy absorption for each of the beams can be determined from the graph based on the enclosed area of each of the curves shown in FIG. 16.

[0045] As shown in FIG. 16, all four beams 200, 300, 400, and 500 exhibited greater ductility (i.e., displacement) and energy absorption than the simple hat-shaped composite beam structure. Furthermore, it can be seen that by changing the number of transition edges and the height of the shelves on the side flanges of the beams, the peak load and displacement of the beams can be changed. For example, beams 300 and 500, which each include a minimum of four transition edges, exhibited higher peak load and lower displacement as compared to beam 400. Beam 400, on the other hand, which includes a minimum of eight transition edges, exhibited higher displacement than the other three beams. In comparison to the peak load of beam 400, the peak load of beam 300 is higher, but the peak load of beam 200 is almost the same as the peak load of beam 400.

[0046] Referring to FIG. 17, an actual load/displacement graph is shown illustrating the test results of a three-point bending test performed on three different beam structures 600, 700, and 800. The simulated test result of the conventional "hat-shaped" composite beam is also included in the graph for comparison with the beam structures of the present application. The beams 600, 700, and 800 are similar in structure to beams 200, 300, and 500, respectively. Each of the beams 600, 700, and 800 were made from a composite material including glass fiber and unsaturated polyester resin with a volume fraction of 54.925%. Each beam was subjected to a three-point bending test to obtain the plots shown in FIG. 17. As shown, all three beams 600, 700, and 800 exhibited greater ductility and energy absorption than the simulated conventional hat-shaped composite beam, which failed after a displacement of around 20 mm. Although the peak loads of the actual test results shown in FIG. 17 are lower than the peak loads of the simulated test results shown in FIG. 16, this difference can be attributed, at least in part, to the difference in materials (i.e., the computer simulation used epoxy resin, whereas the actual test samples used an unsaturated polyester resin), the volume fraction of the materials (i.e., the computer simulation had a volume fraction of 69%, whereas the actual test samples had a volume fraction of 54.925%), and the somewhat limited accuracy of the computer simulation used to produce the plots shown in FIG. 16.

[0047] The various beams disclosed herein are made from a composite material and include a unique structural shape to provide sufficient ductile deformation when subjected to a load, so as to match or exceed the deformation characteristics of steel or other composite beams. In this manner, the composite beams weigh much less than conventional steel beams, but have good ductility to provide for better energy absorption, as compared to conventional steel and composite beams.

[0048] As utilized herein, the terms "approximately," "about," "substantially", and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the application.

[0049] The terms "coupled," "connected," and the like, as used herein, mean the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another.

[0050] References herein to the positions of elements (e.g., "top," "bottom," "above," "below," "upper," "downward," "upwardly," etc.) are merely used to describe the orientation of various elements in the FIGURES. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.

[0051] The construction and arrangement of the elements of the beams, and components thereof, as shown in the exemplary embodiments are illustrative only. Although only a few embodiments of the present disclosure have been described in detail, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied.

[0052] Additionally, the word "exemplary" is used to mean serving as an example, instance, or illustration. Any embodiment or design described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments or designs (and such term is not intended to connote that such embodiments are necessarily

extraordinary or superlative examples). Rather, use of the word "exemplary" is intended to present concepts in a concrete manner. Accordingly, all such modifications are intended to be included within the scope of the present disclosure. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the preferred and other exemplary embodiments without departing from the scope of the application.

[0053] Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present application. For example, any element/component disclosed in one embodiment may be incorporated or utilized with any other embodiment disclosed herein. Also, for example, the order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Any means-plus- function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and omissions may be made in the design, operating configuration, and arrangement of the preferred and other exemplary embodiments without departing from the scope of the application.