Reinforced structural member and method for its manufacture

Abstract

A structural member for the body of a motor vehicle includes a generally elongated support member which at least partially encloses an interior volume, and a reinforcing insert which is disposed in the interior volume. The reinforcing insert extends along at least a portion of the length of the support member, and has a cross section which defines a closed perimeter that encloses an area. The insert member may be configured so as to control its deformation characteristics thereby providing a structural member which efficiently and safely absorbs kinetic energy in a crash.

1 . A structural member for a body of a motor vehicle, said structural member comprising: 
 a generally elongated support member which at least partially encloses an interior volume; and    a reinforcing insert which is disposed within said interior volume and which extends along at least a portion of the length of said support member, said reinforcing insert having a cross section which defines a closed perimeter that encloses an area.    
     
     
         2 . The member of  claim 1 , wherein said cross section of said reinforcing insert is a trapezoidal cross section.  
     
     
         3 . The member of  claim 1 , wherein said reinforcing insert is bonded to an interior surface of said support member.  
     
     
         4 . The member of  claim 3 , wherein said reinforcing insert is adhesively bonded to said interior surface.  
     
     
         5 . The member of  claim 1 , wherein said reinforcing insert has a cross section which defines two spaced-apart portions, said spaced-apart portions being joined together by a connecting portion.  
     
     
         6 . The member of  claim 5 , wherein said spaced-apart portions each comprise a lobe, each lobe having a cross section which defines a perimeter that encloses a separate, respective area.  
     
     
         7 . The member of  claim 6 , wherein at least one of said lobes has a trapezoidal cross section.  
     
     
         8 . The member of  claim 5 , wherein said connecting portion does not have a cross section which defines a perimeter that encloses a respective area.  
     
     
         9 . The member of  claim 6 , wherein said connecting portion has a cross section which defines a perimeter that encloses a separate respective area.  
     
     
         10 . The member of  claim 1 , wherein at least one of said support member and said reinforcing insert are made of steel.  
     
     
         11 . The member of  claim 1 , wherein at least one of said support member and said reinforcing insert are made of roll-formed steel.  
     
     
         12 . A method of making a structural member for a body of a motor vehicle, said method comprising the steps of: 
 providing a generally elongated support member which at least partially encloses an interior volume;    providing a reinforcing insert having a cross section which defines a closed perimeter that encloses an area; and    disposing said reinforcing insert in said interior volume so that said reinforcing insert extends along at least a portion of the length of said support member.    
     
     
         13 . The method of  claim 12  including the step of carrying out a further processing operation on said support member after said reinforcing insert is disposed therein.  
     
     
         14 . The method of  claim 13 , wherein said further processing operation is selected from the group consisting of: roll forming, sweeping, twisting, bending, die forming, cutting, drilling, flattening, crushing, heating, welding, brazing, quenching, and combinations thereof.  
     
     
         15 . The method of  claim 12 , wherein said reinforcing insert is subjected to a processing operation before being inserted into said support member.  
     
     
         16 . The method of  claim 12 , wherein at least one of said support member and said reinforcing insert are roll formed.  
     
     
         17 . The method of  claim 12 , wherein at least one of said support member and reinforcing insert are made of steel.  
     
     
         18 . The method of  claim 12 , including the further step of bonding said reinforcing insert to said support member.  
     
     
         19 . The method of  claim 18 , wherein said step of bonding comprises adhesively bonding said reinforcing insert to said support member.  
     
     
         20 . The method of  claim 12 , wherein said reinforcing insert has a cross section which defines two spaced-apart lobes, said lobes being joined together by a connecting portion.  
     
     
         21 . The method of  claim 12 , wherein said cross section of said reinforcing insert defines a trapezoidal perimeter.  
     
     
         22 . A motor vehicle body which includes the structural member of  claim 1.