Shape Corp.

A beam assembly includes a first beam that has a first tubular portion and a first projecting portion that extends from the first tubular portion. A second beam has a second tubular portion and a second projecting portion that extends from the second tubular portion. The elongated interior of the first tubular portion defines a first hollow area and the elongated interior of the second tubular portion defines a second hollow area. The first beam is attached to the second beam with the first projecting portion attached to the second tubular portion and the second projecting portion attached to the first tubular portion to define a third hollow area between the first and second projecting portions.

A vehicle rocker assembly includes a sill outer and a sill inner that together define an elongated hollow interior. The vehicle rocker assembly also includes a rocker insert disposed within the elongated hollow interior. The rocker insert includes a stiffening member defining a wave-shaped structure and including at least one sheet defining a fore edge, an aft edge, a first side edge and a second side edge opposite the first side edge. Additionally, the fore edge and the aft edge are disposed at different locations along the length of the rocker insert. Moreover, a crest of the wave-shaped structure extends between the first side edge and the second side edge and is configured to carry a load path laterally between the inboard and outboard wall portions.

A multi-tubular beam for a vehicle, such as a vehicle structure or a bumper reinforcement, includes an elongated beam formed with a metal sheet. The metal sheet has a central section and outer sections extending along a length of the metal sheet. The outer sections are disposed in opposing directions from the outer edges of the central section to provide adjacent first and second tubular portions. The central section forms a common center wall between the adjacent first and second tubular portions. A first edge portion of the metal sheet is disposed along and in parallel alignment with the center wall. The first edge portion is attached to the center wall at a first weld joint to form the first tubular portion. The first weld joint includes a weld material that extends through a thickness of the center wall and into a thickness of the first edge portion.

A vehicle rocker assembly may include a sill inner comprising 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 may also include 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. The vehicle rocker assembly also includes a rocker insert disposed within the elongated hollow interior, the rocker insert comprising: an upper wall, a lower wall, and a side wall extending between the upper wall and the lower wall. At least one of the upper wall or the lower wall comprises a corrugated portion that has a ridge oriented to extend in a lateral vehicle direction.

A vehicle rocker assembly includes a tubular insert disposed between a sill inner and a sill outer. The tubular insert may include an inboard wall disposed adjacent the sill inner, an outboard wall disposed adjacent the sill outer, an upper wall extending between upper ends of the inboard and outboard walls, a lower wall extending between lower ends of the inboard and outboard walls, and a center wall disposed between the upper and lower walls. The center wall may extend between the inboard and outboard walls with a length less than the upper and lower walls.

A crossmember for a vehicle floor structure includes a roll-formed beam having an elongated hollow body formed from a metal sheet. The beam is configured to span laterally over a floor panel with opposing ends of the beam coupled to longitudinal members that extend along sides of the floor panel. The beam includes a cross-sectional shape taken transverse to the length of the beam and extending consistently along the length between the opposing ends of the beam. The beam has a first hollow section and a second hollow section extending along the length of the beam, where the first and second hollow sections are interconnected by a narrowed section of the cross-sectional shape. Edges of the metal sheet are welded together along the length of the beam at the narrowed section of the cross-sectional shape.

A vehicle rocker assembly includes a sill inner and a sill outer. An upper flange portion of the sill inner is coupled with an upper flange portion of the sill outer, and a lower flange portion of the sill inner is coupled with a lower flange portion of the sill outer to enclose a hollow interior of the vehicle rocker assembly. One of the sill inner or the sill outer includes a reinforcement structure integrated in the sill wall of the respective still inner or sill outer. The reinforcement structure includes walls that each laterally span the hollow interior and form a multi-hollow cross-sectional shape with the sill inner and sill outer.

A vehicle rocker assembly may include a sill inner comprising 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 may also include 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. The vehicle rocker assembly also includes a rocker insert disposed within the elongated hollow interior, the rocker insert comprising: an upper wall, a lower wall, and a side wall extending between the upper wall and the lower wall. At least one of the upper wall or the lower wall comprises a corrugated portion that has a ridge oriented to extend in a lateral vehicle direction.

A structural component of a vehicle may include an elongated beam having a seamless outer wall surrounding a hollow interior area along the length of the beam. The outer wall defines a closed-cross-sectional shape along the length of the beam and may be comprised of at least four outer wall sections. The outer wall of the elongated beam may include plurality of channels protruding into the hollow interior area and extending laterally from an inboard side to an outboard side on at least one section of the outer wall of the elongated beam. The outer wall includes a flat surface spanning between each of the plurality of channels. The elongated beam may be comprised of an extruded aluminum, and the channels may be formed after extrusion in an orthogonal direction to the direction of extrusion.

A reinforcement beam for an automotive component is continuously formed with a metal sheet that is roll formed to have at least one tubular portion that extends along a length of the reinforcement beam. A solid state forge weld is formed between an edge of the metal sheet and an intermediate portion of the metal sheet to close a seam that extends along the tubular portion of the reinforcement beam. Prior to forming the solid state forge weld, select portions of the metal sheet are heated to a desirable welding temperature with a high frequency current delivered by electrical contacts to opposing sides of the weld seam. The desired welding temperature may burn off a galvanized coating on the metal sheet at the select portions prior to forming the solid state forge weld that is generally void of zinc inclusions.