CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority under 35 U.S.C §119(e) to U.S. Provisional Patent Application No. 63/256,914, filed October 18, 2021, the disclosure of this prior application is considered part of this application and is hereby incorporated by reference in its entirety.

TECHNICAL FIELD

[0002] The present disclosure relates to sill assemblies and more specifically to rocker insert assemblies for vehicle body structures.

BACKGROUND

[0003] 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 insurance requirements and other 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.

[0004] 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 sill assembly such as by adding a rocker insert assembly within the vehicle sill assembly.

SUMMARY

[0005] This disclosure provides a vehicle rocker assembly and a reinforcement insert assembly for a vehicle rocker. The rocker insert provides a center panel or sheet that extends along a hollow interior of the vehicle rocker and includes a channel formed along its length. The rocker insert also includes a tubular member that attached in the channel, so as to form a lateral slip plane that is configured to allow the tubular member to be spaced from the recessed portion of the channel to form an elongated hollow interior therebetween. The assembled thin-walled structure around the hollow interior forms an additional stiffened structure adjacent to the tubular member, such that the rocker insert increases stiffness and directs impact load paths laterally to surrounding vehicle structure that is configured to undergo such impact forces.

[0006] Once aspect of the disclosure provides a vehicle rocker assembly that includes a sill inner and a sill outer coupled with the sill inner to define an elongated hollow interior between the sill inner and the sill outer. A rocker insert is disposed within the elongated hollow interior. The rocker insert includes a center panel that extends between upper and lower flange portions of the sill inner and the sill outer. The center panel includes a channel disposed longitudinally along an intermediate portion of the elongated hollow interior, where the channel includes an upper wall portion and a lower wall portion that are integrally connected by a recessed wall of the channel. A tubular member is coupled with the center panel and at least partially disposed within the channel, such that the tubular member is spaced from the recessed wall of the channel to form a second hollow interior therebetween.

[0007] Implementations of the disclosure may include one or more of the following optional features. In some implementations, the sill inner includes a sill wall portion integrally extending between the upper flange portion and the lower flange portion of the sill inner, and the sill outer comprises a sill wall portion integrally extending between the upper flange portion and the lower flange portion of the sill outer. In some examples, the upper flange portion of the sill inner is coupled with the upper flange portion of the sill outer, and the lower flange portion of the sill inner is coupled with the lower flange portion of the sill outer to define the elongated hollow interior between the sill wall portions of the sill inner and the sill outer.

[0008] In some implementations, the center panel comprises an upper edge portion that is attached between the upper flange portions of the sill inner and the sill outer and a lower edge portion that is attached between the lower flange portions of the sill inner and the sill outer. In some examples, the center panel below the channel defines a lower leg portion that is configured to support the tubular member during lateral crush resulting from a side impact force.

[0009] In some implementations, the lower leg portion has a second channel that provides additional stiffening to the rocker insert. In some examples, a reinforcement may be disposed at the second channel and extend between the second upper wall portion and the second lower wall portion with spacing from the second recessed wall to form a third hollow interior. [0010] In some examples, the tubular member is attached to the upper and lower wall portions of the channel. For instance, the tubular member may include upper and lower walls that are laterally aligned with the upper and lower wall portions of the channel, such that the tubular member is configured to laterally direct side impact forces to an inboard floor cross member of the vehicle.

[0011] In some implementations, the upper and lower wall portions and the recessed wall of the channel together form a U-shaped transverse cross sectional shape. In some examples, the recessed wall is disposed against the sill outer.

[0012] In some implementations, the center panel is formed from one material and the tubular member is formed from a different second material. For example, the center panel in some instances has a single metal sheet that extends between the upper and lower flanges and is separate from the tubular member.

[0013] Another aspect of the disclosure provides a rocker insert assembly for a vehicle rocker that has a sill inner and a sill outer. The rocker insert assembly includes a center panel that has an upper edge portion that is configured to attached between upper flanges of the sill inner and the sill outer and a lower edge portion that is configured to attach between lower flanges of the sill inner and the sill outer. The center panel includes a channel that is disposed between the upper and lower edge portions. The channel includes an upper wall portion and a lower wall portion that are connected by a recessed wall of the channel. A tubular member is disposed within the channel and is attached to the upper and lower wall portions of the channel, such that the tubular member is spaced from the recessed wall of the channel to form a hollow interior laterally adjacent to the tubular member.

[0014] Yet another aspect of the disclosure provides a vehicle rocker assembly that includes a sill panel having upper and lower flanges and defining an elongated hollow interior between the upper and lower flanges. A rocker insert is disposed within the elongated hollow interior and includes a center panel and a tubular member. The center panel extends between the upper and lower flanges of the sill panel and includes a channel disposed longitudinally along an intermediate portion of the elongated hollow interior. The tubular member is coupled with the center panel and is at least partially disposed within the channel. The tubular member is spaced from a recessed wall of the channel to form a second hollow interior therebetween. [0015] A further aspect of the disclosure provides a vehicle rocker assembly that includes an elongated panel that is configured to extend between upper and lower flanges of an adjacent sill panel. The elongated panel has a channel along its length. A tubular reinforcement member is disposed in the channel and coupled with the elongated panel at opposing upper and lower wall portions of the channel. The tubular reinforcement member is spaced from a recessed wall of the channel that integrally interconnects between the opposing upper and lower wall portions to form a hollow interior therebetween. In some examples, the elongated panel is a sill panel having upper and lower flanges configured to couple with the upper and lower flanges of the adjacent sill panel to defining an elongated hollow interior therebetween. In other examples, the rocker assembly also includes a sill panel having upper and lower flanges and defining an elongated hollow interior between the still panel and the adjacent sill panel, such that the elongated panel may form a center panel that is disposed in and along the elongated hollow interior between the sill panel and the adjacent sill panel.

[0016] 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

[0017] FIG. 1 is an upper perspective view of a vehicle showing a vehicle rocker assembly including a rocker insert assembly and other structural components;

[0018] FIG. 2 is a side elevation view of a vehicle schematically showing the rocker assembly including the rocker insert assembly;

[0019] FIG. 3 is a cross-sectional view of an example of the vehicle rocker assembly including the rocker insert assembly;

[0020] FIG. 4A is a perspective view of the example of the rocker insert assembly shown in FIG. 3;

[0021] FIG. 4B is a cross-sectional view of the example of the rocker insert assembly shown in FIG. 4A;

[0022] FIG. 5 is a cross-sectional view of another example of the rocker insert assembly; [0023] FIG. 6 is a cross-sectional view of another example of the rocker insert assembly; [0024] FIG. 7 is a cross-sectional view of another example of the rocker insert assembly;

[0025] FIG. 8 is a cross-sectional view of another example of the rocker insert assembly;

[0026] FIG. 9 is a cross-sectional view of another example of the rocker insert assembly;

[0027] FIG. 10 is a cross-sectional view of another example of the rocker insert assembly; and

[0028] FIG. 11 is a cross-sectional view of another example of the rocker insert assembly.

[0029] Like reference numerals indicate like parts throughout the drawings.

DETAILED DESCRIPTION

[0030] 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 101 as shown in FIGS. 1 and 2. The vehicle frame 101 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 2, the vehicle frame has various structural component, including a B-pillar 103, a hinge pillar 104, a floor cross-member 105, a roof bow 106, and a header 107, among other 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 108 generally located between the axles and below the floor 109 44to distribute the battery weight and establish a low center of gravity for the vehicle.

[0031] The vehicle rocker component 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 oriented in FIG. 1. As shown in FIGS. 2 and 3, the example of the vehicle rocker assembly 10 is provided with a reinforcement insert assembly disposed in the interior area 16 to form a multi -tubular rocker structure. The rocker assembly 10 shown in FIG. 3 is disposed alongside an outer section of a battery tray 108 with the floor cross-member 105 being attached to the vehicle rocker assembly 10 so as to span laterally over the battery tray 108. 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. [0032] When designing the vehicle rocker assembly with a rocker insert assembly 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 assembly 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 assembly 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.

[0033] Moreover, the rocker insert assembly disclosed herein may be formed with a 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, such as to provide higher stiffness and impact energy absorption, occupy a smaller packaging space, and have greater flexibility in the outer shape design. The cross-sectional shape of different examples of the vehicle component and rocker insert assembly may include various shapes and thicknesses for the desired application of the vehicle component.

[0034] 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.

[0035] Referring now to the vehicle rocker assembly 10 shown in FIG. 3, 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. 3 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. 3 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.

[0036] As further shown in FIG. 3, 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 joined 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.

[0037] 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 corner 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 corner 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. 3, 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. 3, 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. 3, such as approximately between 40 and 120 degrees, between 70 and 100 degrees, between 80 and 95 degrees, or between 82 and 92 degrees.

[0038] As also shown in FIG. 3, 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 corner 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 corner 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 corner 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. 4, such as approximately between 40 and 120 degrees, between 70 and 100 degrees, between 80 and 95 degrees, or between 82 and 92 degrees.

[0039] As shown in FIG. 3, 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 assembly 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.

[0040] As further shown in FIGS. 3, 4A, and 4B, the vehicle rocker assembly 10 includes a rocker insert assembly 40 disposed within the elongated hollow interior 16. The rocker insert assembly 40 includes a center panel 42 extending between the upper and lower flange portions 18, 20, 22, 24 of the sill inner 12 and sill outer 14. The center panel 42 may also be referred to as a membrane or a middle plate. The center panel 42 has an upper edge portion 44 attached between the upper flange portions 18, 22 of the sill inner 12 and the sill outer 14. The center panel 42 also includes a lower edge portion 46 attached between the lower flange portions 20, 24 of the sill inner 12 and the sill outer 14. Having upper and lower edge portions 44, 46 attached to between the upper and lower flange portions 18, 20, 22, 24 of the sill inner 12 and the sill outer 14 provides strength and stability to the rocker insert assembly 40. The attachment between the upper flange portions 18, 22 of the sill inner 12 and the sill outer 14 and the upper edge portion 44 may be a weld attachment, however, various other or additional attachment methods are contemplated. Additionally, when assembling the vehicle rocker assembly 10 the center panel 42 may be first attached to the sill inner 12 and then inserted to be attached to the sill outer 14. Alternatively, the vehicle rocker assembly 10 may be assembled by first attaching the center panel 42 of rocker insert assembly 40 to the sill outer 14 before being attached to the sill inner 12.

[0041] Referring still to FIGS. 3, 4A, and 4B, the center panel 42 also defines a channel 48 disposed between the upper and lower edge portion 44, 46 and extending along the elongated hollow interior. The channel 48 including an upper wall portion 50 and a lower wall portion 52 that are connected by a recessed wall 56 of the channel 48. In some examples, the recessed wall 56 has sharp corners such as defining an approximately 90 degree angle. In other examples, the recessed wall 56 has rounded corners. Additionally, other examples include other shaped corners such as partially rounded or angles other than 90 degrees. In some examples, the center panel 42 may also define a second channel 54 disposed between the first channel 48 and the lower edge portion 46. It is also contemplated that a third channel or other shapes may be present in the center panel 42, as described in more detail below and shown in FIGS. 5-11.

[0042] The rocker insert assembly 40 also includes a tubular member 60 at least partially disposed within the channel 48 and attached to the upper and lower wall portions 50, 52 of the channel 48. Again, it is contemplated that the attachment mechanism between the tubular member 60 and the center panel 42 may be welding attachment, as shown in FIGS. 3, 4 A, and 4B, however, various other attachment methods have been contemplated. In some examples, the center panel 42 is a single sheet and the tubular member 60 is a separate piece from the center panel 42, however, other variations have been contemplated. Additionally, the center panel 42 may be comprised a first material and the tubular member 60 may be comprised of a second material which is different than the first material of the center panel 42. One or more of the first material or the second material may be aluminum, steel, or other materials configured to provide the strength desired for the rocker insert assembly 40.

[0043] Additionally, as shown in FIGS. 3, 4A, and 4B, the tubular member 60 is spaced from the recessed wall 56 of the channel 48 to form a second hollow interior 62 extending along the elongated hollow interior of the vehicle rocker assembly 10. However, it is also contemplated that the tubular member 60 may be nested within the recessed wall 56 of the channel 48 to form a second hollow interior 62 extending along the elongated hollow interior of the vehicle rocker assembly 10. In the example where the tubular member 60 is nested within the recessed wall 56 of the channel, the tubular member 60 may be attached, such as by welding or other coupling methods, to one or more portions of the recessed wall 56, the upper wall portion 50, or the lower wall portion 52. In the example shown in FIGS. 3, 4A, and 4B, the tubular member 60 is generally rectangular in shape, having curved corners defining a generally rectangular elongate second hollow interior 62. However, it is also contemplated that the tubular member 60 may be various shapes and sizes and define any shape and size second hollow interior as shown in FIGS. 5-11 and as described in more detail below. As also shown in FIGS. 3, 4A, and 4B, the tubular member 60 is laterally or horizontally aligned with the channel 48 of the center panel 42. Additionally, the tubular member 60 is laterally aligned with the floor cross member, so that side impact forces imparted form a side collision to the vehicle are substantially directed to the floor cross member. Accordingly, the channel and tubular member are disposed in the hollow interior at a vertical height that is laterally or horizontally aligned with the floor cross member.

[0044] Referring still to the example shown in FIGS. 3, 4A, and 4B, the center panel 42 below the channel 48 includes a lower leg portion 64 that is configured to support the tubular member 60 during lateral crush resulting from a side impact force. In other words, the lower leg portion 64 prevents rotation of the tubular member when undergoing horizontal forces and crushing inboard, as such rotation would significantly reduce the energy absorption potential of the tubular member. As briefly described above, the lower leg portion 64 may include a second channel 54 portion defined by a second upper wall portion 50 and a second lower wall portion 52 that are connected by a second recessed wall 56 of the channel 48. The second recessed wall 56 of the second channel 54 may be a similar size to the first recessed wall 56 of the second channel 54 such that the first channel 48 and the second channel 54 have similar sizes and shapes. However, various other sizes and shapes have been contemplated. Additionally, as shown in FIGS. 3, 4A, and 4B, a plate 66 is provided over the second channel 54 by extending from the second upper wall portion 50 to the second lower wall portion 52 and disposed opposite to the second recessed wall 56. The plate 66 may be attached to the second upper wall portion 50 and to the second lower wall portion 52 by welding, as illustrated in FIGS. 3, 4A, and 4B or may be attached by another method. Similar to the tubular member, the plate 66 to provide another hollow area that stiffens and strengthens the lower leg portion 64 and its function of stabilizing the tubular member.

[0045] Various other examples of rocker insert assemblies are illustrated in FIGS. 5-10. They are described using similar reference numbers to the example shown in FIGS. 3, 4 A, and 4B increased by a factor of 100. The example rocker insert assembly 140 shown in FIG. 5 includes many of the same features as described above including but not limited to a center panel 142 extending between the upper and lower flange portions 18, 20, 22, 24 of the sill inner 12 and sill outer 14, the center panel 42 having an upper edge portion 44 attached between the upper flange portions 18, 22 of the sill inner 12 and the sill outer 14 and a lower edge portion 46 attached between the lower flange portions 20, 24 of the sill inner 12 and the sill outer 14. Additionally, similar to the example shown in FIGS. 3, 4 A, and 4B, the example rocker insert assembly 140 shown in FIG. 5 also includes the center panel 142 including a channel 148 disposed between the upper and lower edge portion 144, 146 and extending along the elongated hollow interior, the channel 148 including an upper wall portion 150 and a lower wall portion 152 that are connected by a recessed wall 156 of the channel 148. Moreover, the example shown in FIG. 5 also includes a tubular member 160 at least partially disposed within the channel 148 and attached to the upper and lower wall portion 50,52 of the channel 148 with the tubular member 160 being spaced from the recessed wall 156 of the channel 148 to form a second hollow interior 162. However, in the example shown in FIG. 5, the tubular member 160 has an outer portion similar shaped to the tubular portion in FIGS. 3, 4 A, and 4B, while an inner portion has a trapezoidal shape with upper and lower edges angled toward one another providing a more narrow tubular channel 148 area on the outer side.

[0046] Referring now to the example shown in FIG. 6, the example rocker insert assembly 240 shown in FIG. 6 includes many of the same features as described above with respect to FIGS. 3, 4A, and 4B, including but not limited to a center panel 242 extending between the upper and lower flange portions 18, 20, 22, 24 of the sill inner 12 and sill outer 14, the center panel 242 having an upper edge portion 244 attached between the upper flange portions 18, 22 of the sill inner 12 and the sill outer 14 and a lower edge portion 246 attached between the lower flange portions 20, 24 of the sill inner 12 and the sill outer 14. Additionally, similar to the example shown in FIGS. 3, 4A, and 4B, the example rocker insert assembly 240 shown in FIG. 6 also includes the center panel 242 including a channel 248 disposed between the upper and lower edge portion 244, 246 and extending along the elongated hollow interior, the channel 248 including an upper wall portion 250 and a lower wall portion 252 that are connected by a recessed wall 256 of the channel 248. Moreover, the example shown in FIG. 6 also includes a tubular member 260 at least partially disposed within the channel 48 and attached to the upper and lower wall portions 250, 252 of the channel 248 with the tubular member 260 being spaced from the recessed wall 256 of the channel 248 to form a second hollow interior 262. However, in the example shown in FIG. 6, the center panel 242 includes the second channel 254 portion including the second upper wall portion 250 and the second lower wall portions 252 that are connected by the second recessed wall 256. Additionally, the tubular member 260 also includes a lower tubular member 260b at least partially disposed within the second channel 254 portion and having a similar shape and size to the upper tubular member 260a. Moreover, as shown in FIG. 6, the lower tubular member 260b integral with the upper tubular member 260a such that a connecting portion 261 is disposed between the upper tubular member 260a and the lower tubular member 260b which connects the two tubular members 260a, b. In the example shown, the connecting portion 261 is disposed away from the center panel 242 and towards the inner sill member, however, various other locations for connecting portions 261 have been contemplated.

[0047] Referring now to the example shown in FIG. 7, the example rocker insert assembly 340 shown in FIG. 7 includes many of the same features as described above with respect to FIGS. 3, 4A, and 4B, including but not limited to a center panel 342 extending between the upper and lower flange portions 18, 20, 22, 24 of the sill inner 12 and sill outer 14, the center panel 342 having an upper edge portion 344 attached between the upper flange portions 18, 22 of the sill inner 12 and the sill outer 14 and a lower edge portion 346 attached between the lower flange portions 20, 24 of the sill inner 12 and the sill outer 14. Additionally, similar to the example shown in FIGS. 3, 4A, and 4B, the example rocker insert assembly 340 shown in FIG. 7 also includes the center panel 342 including a channel 348 disposed between the upper and lower edge portion 344, 346 and extending along the elongated hollow interior, the channel 348 including an upper wall portion 350 and a lower wall portion 352 that are connected by a recessed wall 356 of the channel 348. Moreover, the example shown in FIG. 7 also includes tubular members 360a, 360b, each having a hollow interior 362a, 362b and at least partially disposed within the channel 348 and attached to the upper and lower wall portions 350, 352 of the channel 348 with the tubular member 360 being spaced from the recessed wall 356 of the channel 348 to form a second hollow interior therebetween. However, in the example shown in FIG. 7, the center panel 342 includes the second channel 354 portion including the second upper wall portion 350 and the second lower wall portion 352 that are connected by the second recessed wall 356. Additionally, the tubular member 360 also includes a lower tubular member 360b at least partially disposed within the second channel 354 portion and having a similar shape and size to the upper tubular member 360a. Moreover, as shown in FIG. 7, the lower tubular member 360b is a separate piece from the upper tubular member 360a such that the lower tubular member 360b and the upper tubular member 360a are not connected.

[0048] Referring now to the example shown in FIG. 8, the example rocker insert assembly 440 shown in FIG. 8 includes many of the same features as described above with respect to FIGS. 3, 4A, and 4B, including but not limited to a center panel 442 extending between the upper and lower flange portions 18, 20, 22, 24 of the sill inner 12 and sill outer 14, the center panel 442 having an upper edge portion 444 attached between the upper flange portions 18, 22 of the sill inner 12 and the sill outer 14 and a lower edge portion 446 attached between the lower flange portions 20, 24 of the sill inner 12 and the sill outer 14. Additionally, similar to the example shown in FIGS. 3, 4A, and 4B, the example rocker insert assembly 440 shown in FIG. 8 also includes the center panel 442 including a channel 448 disposed between the upper and lower edge portion 444, 446 and extending along the elongated hollow interior, the channel 448 including an upper wall portion 450 and a lower wall portion 452 that are connected by a recessed wall 456 of the channel 448. Moreover, the example shown in FIG. 8 also includes a tubular member 460 at least partially disposed within the channel 448 and attached to the upper and lower wall portion 450, 452 of the channel 448 with the tubular member 460 being spaced from the recessed wall 456 of the channel 448 to form a second hollow interior 462. However, in the example shown in FIG. 8, the tubular member 460 has sharp angled comers, such as 90 degree angles, as opposed to the rounded corners described above with respect to the example shown in FIGS. 3, 4 A, and 4B.

[0049] Referring now to the example shown in FIG. 9, the example rocker insert assembly 540 shown in FIG. 9 includes many of the same features as described above with respect to FIGS. 3, 4A, and 4B, including but not limited to a center panel 542 extending between the upper and lower flange portions 18, 20, 22, 24 of the sill inner 12 and sill outer 14, the center panel 542 having an upper edge portion 544 attached between the upper flange portions 18, 22 of the sill inner 12 and the sill outer 14 and a lower edge portion 546 attached between the lower flange portions 20, 24 of the sill inner 12 and the sill outer 14. Additionally, similar to the example shown in FIGS. 3, 4A, and 4B, the example rocker insert assembly 540 shown in FIG. 9 also includes the center panel 542 including a channel 548 disposed between the upper and lower edge portion 544, 546 and extending along the elongated hollow interior 562, the channel 548 including an upper wall portion 550 and a lower wall portion 552 that are connected by a recessed wall 556 of the channel 548. Moreover, the example shown in FIG. 9 also includes a tubular member 560 at least partially disposed within the channel 548 and attached to the upper and lower wall portions 550, 552 of the channel 548 with the tubular member 560 being spaced from the recessed wall 556 of the channel 548 to form a second hollow interior 562. However, in the example shown in FIG. 9, the tubular member 560 is comprised of a sheet folded such that it forms two tubular members 560 extending adjacent to one another, i.e. an inner tubular member 560a and an outer tubular member 560b. The outer tubular member 560b is at least partially disposed within the channel 548 and the inner tubular member 560a is disposed closer to the inner sill 12 and further from the channel 548. Moreover, in the example shown in FIG. 9, the inner tubular member 560a and the outer tubular member 560b share a vertical wall therebetween. However, various other configurations of inner tubular member 560a and outer tubular member 560b have been contemplated.

[0050] Referring now to the example shown in FIG. 10, the example rocker insert assembly 640 shown in FIG. 10 includes many of the same features as described above with respect to FIGS.

3, 4 A, and 4B, including but not limited to a center panel 642 extending between the upper and lower flange portions 18, 20, 22, 24 of the sill inner 12 and sill outer 14, the center panel 642 having an upper edge portions 44 attached between the upper flange portions 18, 22, of the sill inner 12 and the sill outer 14 and a lower edge portion 646 attached between the lower flange portions 20, 24 of the sill inner 12 and the sill outer 14. Additionally, similar to the example shown in FIGS. 3, 4A, and 4B, the example rocker insert assembly 640 shown in FIG. 10 also includes the center panel 642 including a channel 648 disposed between the upper and lower edge portion 644, 646 and extending along the elongated hollow interior, the channel 468 including an upper wall portion 650 and a lower wall portion 652 that are connected by a recessed wall 656 of the channel 648. Moreover, the example shown in FIG. 10 also includes a tubular member 660 at least partially disposed within the channel 648 and attached to the upper and lower wall portion 650, 652 of the channel 648 with the tubular member 660 being spaced from the recessed wall 656 of the channel 648 to form a second hollow interior 662. However, in the example shown in FIG. 10, the upper and lower wall portion 650, 652 each have an angled portion 668, 670 which extend away from one another and connected by the recessed wall 656 which is longer than previous examples. The upper and lower wall portions 650, 652 may extend away from one another at an angle of approximately 45 degrees as shown in FIG. 10. However, various other angles have been contemplated including but not limited to angles of 30-60 degrees, angles of 40-50 degrees, and the like. As additionally illustrated in FIG. 10, the upper edge portion 644 of the center panel 642 and the lower edge portion 646 of the center panel 642 are not lined up such that one of the upper wall portion 650 or the lower wall portion 652 extends further towards the sill inner 12 than the other.

[0051] Finally, referring now to the example shown in FIG. 11, the example rocker insert assembly 740 shown in FIG. 11 includes many of the same features as described above with respect to FIGS. 3, 4 A, and 4B, including but not limited to a center panel 742 extending between the upper and lower flange portions 18, 20, 22, 24 of the sill inner 12 and sill outer 14, the center panel 742 having an upper edge portion 744 attached between the upper flange portions 18, 22 of the sill inner 12 and the sill outer 14 and a lower edge portion 746 attached between the lower flange portions 20, 24 of the sill inner 12 and the sill outer 14. Additionally, similar to the example shown in FIGS. 3, 4A, and 4B, the example rocker insert assembly 740 shown in FIG. 11 also includes the center panel 742 including a channel 748 disposed between the upper and lower edge portion 744, 746 and extending along the elongated hollow interior, the channel 748 including an upper wall portion 750 and a lower wall portion 752 that are connected by a recessed wall 756 of the channel 748. Moreover, the example shown in FIG. 11 also includes a tubular member 760 having two hollow interiors 762a, 762b, the tubular member 760 being at least partially disposed within the channel 748 and attached to the upper and lower wall portions 750, 752 of the channel 748 with the tubular member 760 being spaced from the recessed wall 756 of the channel 748 to form a second hollow interior. However, in the example shown in FIG. 11, the center panel 742 includes the second channel 754 portion including the second upper wall portion 750 and the second lower wall portions 752 that are connected by the second recessed wall 756. Additionally, the tubular member 760 also includes a lower tubular member 760 at least partially disposed within the second channel 754 portion. Moreover, as shown in FIG. 11, the lower tubular member 760 and the upper tubular member 760 are integral and include the connecting portion therebetween, as described above with respect to FIG. 6. Additionally, the lower wall portion 752 of the first channel 748 portion and the upper wall portion 750 of the second channel 754 extend at an angle of approximately 45 degrees from the respective recessed wall 756 portions towards one another. However, various other angles of extension have also been contemplated including but not limited to angles of 30-60 degrees, 40-50 degrees, and the like. Moreover, the tubular member 760 may have corresponding shapes to the angle of extension to accommodate the angle of the lower wall portion 752 of the first channel 748 and the upper wall portion 750 of the second channel 754. In other words one or more of the upper tubular member 760 and the lower tubular member 760 may have cut-off corner sections to accommodate and facilitate attachment of the upper tubular member 760 and the lower tubular member 760 to the respective first channel 748 and second channel 754. [0052] The inner and outer sill panels 12, 14 and rocker insert assembly 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 panel or membrane of rocker insert assembly 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 assembly 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 assembly 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 assembly 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 assembly. 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 assembly 40 and one of the sill inner 12 and the sill outer 14 may provide additional strength to the vehicle rocker assembly.

[0053] 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 battery tray frames and 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.

[0054] For purposes of this disclosure, the term “coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature; may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components; and may be permanent in nature or may be removable or releasable in nature, unless otherwise stated.

[0055] 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.

[0056] 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. [0057] 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.

[0058] 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.