Energy absorbing side rail

Patent metadata

Field	Value
Publication number	US-12441405-B2
Application number	US-202217743211-A
Country	US
Kind code	B2
Filing date	May 12, 2022
Priority date	May 14, 2021
Publication date	Oct 14, 2025
Grant date	Oct 14, 2025

Abstract

An energy absorbing side rail including an inner rail, an outer rail fixedly coupled to the inner rail defining a cavity, the outer rail defining triggers extending along at least a portion of the outer rail, and at least one energy absorber housed in the cavity, wherein at least one energy absorber is positioned in-line with the triggers.

First claim

What is claimed is:

1. An energy absorbing side rail, comprising:
an inner rail;
an outer rail comprising a top portion, a bottom portion, and an outside portion extending outward from the top portion and the bottom portion, the outer rail fixedly coupled to the inner rail forming a cavity defined by the inner rail, the top portion, and the bottom portion, and wherein the outer rail defines triggers extending along at least a portion of the outer rail; and
at least one energy absorber coupled to the inner rail and housed in the cavity, the inner rail comprising two raised projections defining a channel, the channel being configured to retain the at least one energy absorber via a press fit, wherein the at least one energy absorber is positioned in-line with the triggers.

2. The energy absorbing side rail of claim 1 , wherein the at least one energy absorber is formed of a plastic.

3. The energy absorbing side rail of claim 2 , wherein the at least one energy absorber is formed of a polyphenylene ether and polyamide blend.

4. The energy absorbing side rail of claim 1 , wherein the inner rail and the outer rail are formed of martensitic steel.

5. The energy absorbing side rail of claim 1 , wherein the inner rail and the outer rail are formed of aluminum.

6. The energy absorbing side rail of claim 1 , wherein the triggers are defined on the bottom portion and the top portion.

7. An energy absorbing side rail assembly, comprising:
a vehicle;
an inner rail coupled to the vehicle;
an outer rail comprising a top portion, a bottom portion, and an outside portion extending outward from the top portion and the bottom portion, the outer rail coupled to the inner rail forming a cavity defined by the inner rail, the top portion, and the bottom portion, and wherein the outer rail defines triggers extending along at least a portion of the outer rail; and
at least one energy absorber housed in the cavity, and coupled to the inner rail, the inner rail comprising two raised projections defining a channel, the channel being configured to retain the at least one energy absorber via a press fit, wherein the at least one energy absorber is positioned in-line with the triggers.

8. The assembly of claim 7 , wherein the inner rail is coupled to the vehicle mechanically.

9. The assembly of claim 7 , wherein the inner rail is coupled to the vehicle chemically.

10. The assembly of claim 7 , wherein the inner rail conforms to the shape of a vehicle component of the vehicle.

11. The assembly of claim 10 , wherein the vehicle component is a battery box.

12. The assembly of claim 11 , wherein the inner rail is coupled to the battery box.

13. A method of forming an energy absorbing side rail, the method comprising:
forming an inner rail and an outer rail, wherein the outer rail comprises a top portion, a bottom portion, and an outside portion extending outward from the top portion and the bottom portion;
forming at least one energy absorber;
assembling the inner rail and the outer rail to form a cavity, the cavity defined by the inner rail, the top portion of the outer rail, and the bottom portion of the outer rail; and
positioning at least one energy absorber within the cavity to form an energy absorbing side rail, wherein positioning the at least one energy absorber within the cavity comprises positioning the at least one energy absorber within a channel defined by the inner rail, the channel formed by two raised projections within the inner rail, and coupling the at least one energy absorber to the inner rail, the channel configured to retain the at least one energy absorber via a press fit.

14. The method of claim 13 , further comprising coating the energy absorbing side rail to form a coated energy absorbing side rail.

15. The method of claim 14 , wherein coating the energy absorbing side rail includes electrostatic coating.

16. The method of claim 13 , wherein forming the inner rail and the outer rail includes roll forming.

17. The method of claim 13 , wherein forming the at least one energy absorber includes injection molding.

18. The method of claim 13 , further comprising coupling the energy absorbing side rail to a vehicle component.

Assignees

• Flex N Gate Advanced Product Dev Llc

Inventors

• Brooks Geoffrey
• Perucca Steve
• Fontichiaro Robert L
• Chiang John
• Martini Paul
• Bezaire Derek
• Boyer Aaron

Classifications

• B60K2001/0438

  Arrangement under the floor · CPC title

• B62D25/025

  Side sills thereof · CPC title

• B62D25/2036

  the subunits being side panels, sills or pillars (B62D21/157 takes precedence) · CPC title

• F16F7/12

  using plastic deformation of members {(F16F9/30 takes precedence; yieldable means for mounting bumpers on vehicles B60R19/26; yieldable or collapsible steering columns B62D1/192)} · CPC title

• B60Y2306/01

  Reducing damages in case of crash, e.g. by improving battery protection · CPC title