Vehicle rock rails with energy absorbing structures and associated methods for manufacture

Patent metadata

Field	Value
Publication number	US-11787482-B1
Application number	US-202217739449-A
Country	US
Kind code	B1
Filing date	May 9, 2022
Priority date	May 9, 2022
Publication date	Oct 17, 2023
Grant date	Oct 17, 2023

Abstract

Rock rail assemblies are provided for motor vehicles. An exemplary rock rail assembly may include a beam structure, an energy absorbing structure, and an outer skin. The energy absorbing structure may reinforce the beam structure and may be configured to distribute point loads when an obstacle impinges upon the rock rail assembly. The beam structure may be made of a metallic material, the energy absorbing structure may be made of a foamed polymer-based material, and the outer skin may be made of a polymer-based material. The rock rail assemblies may be constructed in a manufacturing method that involves roll forming and extrusion processes.

First claim

What is claimed is:

1. A rock rail assembly for a motor vehicle, comprising:
a beam structure;
an energy absorbing structure secured to the beam structure to establish a reinforced subassembly of the rock rail assembly; and
an outer skin formed about the reinforced subassembly.

2. The rock rail assembly as recited in claim 1 , wherein the energy absorbing structure is secured to a bottom surface of the beam structure.

3. The rock rail assembly as recited in claim 1 , wherein the beam structure is a steel beam.

4. The rock rail assembly as recited in claim 3 , wherein the steel beam includes a box-like structure and a weld seam.

5. The rock rail assembly as recited in claim 1 , wherein the energy absorbing structure is comprised of a foamed polymer-based material.

6. The rock rail assembly as recited in claim 5 , wherein the foamed polymer-based material includes a high density polyethylene (HDPE) that is modified by a foaming agent.

7. The rock rail assembly as recited in claim 6 , wherein the foamed polymer-based material includes an adhesive resin.

8. The rock rail assembly as recited in claim 1 , wherein the outer skin encapsulates the reinforced subassembly.

9. The rock rail assembly as recited in claim 1 , wherein the outer skin is comprised of a polymer-based material.

10. The rock rail assembly as recited in claim 9 , wherein the polymer-based material includes a high density polyethylene (HDPE).

11. The rock rail assembly as recited in claim 10 , wherein the polymer-based material includes an adhesive resin.

12. The rock rail assembly as recited in claim 1 , comprising at least one opening formed in the beam structure, wherein the at least one opening is configured for receiving a mechanical fastener.

13. A motor vehicle, comprising:
a vehicle body structure; and
a rock rail assembly mounted to the vehicle body structure,
wherein the rock rail assembly includes a beam structure, an energy absorbing structure secured to the beam structure to establish a reinforced subassembly, and an outer skin formed around the reinforced subassembly.

14. The motor vehicle as recited in claim 13 , wherein the beam structure is made of a metallic material, the energy absorbing structure is made of a foamed polymer-based material, and the outer skin is made of a polymer-based material.

15. The motor vehicle as recited in claim 14 , wherein the foamed polymer-based material includes a high density polyethylene (HDPE) that is modified by a foaming agent.

16. The motor vehicle as recited in claim 14 , wherein the metallic material includes steel.

17. The motor vehicle as recited in claim 14 , wherein the polymer-based material includes a high density polyethylene (HDPE) that is modified by an adhesive resin.

18. The motor vehicle as recited in claim 13 , wherein at least one opening is formed in the beam structure, and further wherein a mechanical fastener is received through the vehicle body structure and the at least one opening.

19. The motor vehicle as recited in claim 18 , wherein the mechanical fastener attaches to a U-nut within an interior area of the beam structure.

20. A method for manufacturing a rock rail assembly for a motor vehicle, comprising:
roll forming a beam structure;
extruding an energy absorbing structure onto the beam structure to form a reinforced subassembly of the rock rail assembly; and
extruding an outer skin about the reinforced subassembly.

Assignees

• Ford Global Tech Llc

Inventors

• Dellock Paul Kenneth
• Glickman David Brian
• Salter Stuart C
• Reed Patrick

Classifications

• B62D25/2072 Primary

  Floor protection, e.g. from corrosion or scratching (floor mats B60N3/04, armour F41H7/042, insulation B60R13/08, streamlining B62D35/02) · CPC title

• B60R3/002 Primary

  Running boards (for vehicle tops B60R3/005; at the sides of the vehicle for carrying loads B60R9/02) · CPC title

• B62D21/15 Primary

  having impact absorbing means, e.g. a frame designed to permanently or temporarily change shape or dimension upon impact with another body (bumpers B60R19/02; shock absorbers in general F16F) · CPC title

• B62D21/157

  for side impacts · CPC title

• B62D21/04

  single longitudinal type · CPC title