CN116457267A - Pedal assembly insert with opposing compression grooves - Google Patents

Abstract

A vehicle step assembly includes an outer threshold member and an inner threshold member attached longitudinally along the outer threshold member to define a hollow space along and between the inner and outer threshold members. The tubular insert is disposed in the hollow space to extend longitudinally along the hollow space. The tubular insert has crush-control features extending longitudinally along walls of the tubular insert, such as an upper wall and a lower wall at opposite sides of the interior volume. The tubular insert is configured for lateral impact force at the outer threshold member to laterally deform the tubular insert at the crush control feature to provide accordion-type lateral crush to absorb the lateral impact force.

Description

Pedal assembly insert with opposing compression grooves

Cross Reference to Related Applications

The present application claims priority from U.S. patent application Ser. No. 63/073,120, filed on even 1/9/2020, 35U.S. C ≡119 (e), the disclosure of which is considered a part of the present application and incorporated herein by reference in its entirety.

Technical Field

The present disclosure relates to a step and rocker assembly for a vehicle, such as a step structure having a reinforcement insert.

Background

Vehicles typically have a rigid frame and a body structure, which is commonly referred to as an integrated frame. The frame and body structure are designed to support the vehicle during operation and to withstand and absorb a level of impact forces, such as preventing intrusion into the cabin, trunk, engine compartment, etc., in accordance with insurance requirements and other regulatory and legal requirements. With respect to impact reinforcements and structural beams used in vehicle bodies or frames, it is generally known that these beams may be reinforced with internal inserts to increase stiffness. The pedal assembly extends longitudinally along a lower portion of the integrated frame and is known to have inserts to increase stiffness, for example to reduce side impact intrusion.

Disclosure of Invention

The present disclosure provides a step assembly for a vehicle frame that includes a hollow outer structure formed with attached inner and outer threshold members. The reinforcing insert is disposed within and extends longitudinally along the interior space of the hollow outer structure. The stiffening insert has a generally uniform cross-sectional profile along the length of the tread assembly to provide a tubular shape having one or more closed tubular sections. The reinforcing inserts may be roll formed, stamped or extruded to have a uniform cross-sectional profile, such as a closed or other tubular cross-sectional shape. To increase the impact energy absorption from the side impact forces transferred to the outer threshold member, such as a side rail impactor, the reinforcing insert is provided with one or more lateral compression control features. The compression control features help control lateral compression and deformation of the pedal assembly when subjected to an impact force, such as by laterally deforming the tubular insert in an accordion lateral compression manner by the side impact force. The crush-control features may be provided as crush grooves formed along the reinforcing inserts to protrude into the interior volume of the tubular shape. The crush grooves may be disposed at opposite sides of the reinforcing insert, such as at the upper and lower walls of the closed tubular section of the reinforcing insert, for side impact forces to laterally deform the tubular insert at the crush grooves and provide inward or outward fold deformation, such as accordion-like lateral crushing.

In accordance with one aspect of the present disclosure, a vehicle step assembly includes an outer threshold member and an inner threshold member attached longitudinally along the outer threshold member to define a hollow space along and between the inner and outer threshold members. The tubular insert is disposed in the hollow space to extend longitudinally along the hollow space. The tubular insert has an upper wall and a lower wall that define opposite sides of an interior volume of the tubular insert. The upper and/or lower wall of the tubular insert has a crush groove extending longitudinally along the tubular insert. The crush groove or crush grooves are configured to laterally deform the tubular insert against a lateral impact force at the outer threshold member to provide accordion-like lateral crush to at least partially absorb the lateral impact force.

Implementations of the disclosure may include one or more of the following optional features. In some embodiments, the tubular insert comprises an outer tubular section and an inner tubular section integrally formed together and arranged laterally adjacent to each other. The outer tubular section and the inner tubular section may share a common central wall extending vertically between the upper and lower walls of the tubular insert. In some examples, the outer tubular section has an outer wall facing the outer threshold member and integrally interconnected between the upper and lower walls of the tubular insert.

In some embodiments, the crush groove or crush grooves protrude into the interior volume of the tubular insert, and two or more channels may be disposed at the upper and lower walls at opposite sides of the interior volume. In some examples, the crush groove may be mirrored across the interior volume of the tubular insert, such as at the outer tubular section or the inner tubular section. In other examples, the extrusion grooves are vertically staggered relative to each other. Furthermore, the upper and lower walls of the tubular insert may be arranged in planar parallel alignment with each other, or may have a tapered shape. In some examples, the extrusion groove is vertically aligned across the interior volume of the outer tubular section, e.g., vertically aligned with respect to the upper and lower walls. The pressing groove of the tubular insert may be configured to be deformed simultaneously under a lateral impact force at the outer sill member.

With regard to the fixation of the tubular insert, a bracket may be attached between the upper flanges of the outer and inner threshold members, wherein the bracket is attached to the tubular insert and supports the tubular insert in the hollow space. Further, in some embodiments, the tubular insert comprises a flange attached between the outer and the upper flange of the inner threshold member, wherein the flange supports the tubular insert in the hollow space. Further, the tubular insert may be fixed at the inner surface of the outer or inner sill member, for example by at least one of welding, fasteners or adhesive.

In some examples, the tubular insert comprises a metal plate having an outer tubular section and an inner tubular section with a common central wall, the outer tubular section and the inner tubular section being disposed laterally adjacent to one another. Alternatively, the tubular insert may be longitudinally extruded to have an outer tubular section and an inner tubular section sharing a common wall integrally interconnected with the upper and lower walls of the tubular insert.

The details of one or more implementations of the disclosure are set forth in the accompanying drawings and the description below. Other aspects, features, and advantages will be apparent from the description and drawings, and from the claims.

Drawings

Fig. 1 is a side view of the vehicle outline schematically showing the position of the pedal assembly.

Fig. 2 is a top perspective view of the vehicle of fig. 1 showing the step assembly and various other structural beams.

Figure 3 is a top plan view of the pedal assembly.

Figure 4 is a side plan view of the pedal assembly shown in figure 3.

Figure 4A is a cross-sectional view of the pedal assembly taken along line A-A in figure 4.

Figure 4B is a cross-sectional view of the pedal assembly taken along line B-B of figure 4.

Fig. 5 is a top plan view of another example of a pedal assembly.

Figure 6 is a side plan view of the pedal assembly shown in figure 5.

Figure 6A is a cross-sectional view of the pedal assembly taken along line A-A in figure 6.

Figure 6B is a cross-sectional view of the pedal assembly taken along line B-B in figure 6.

Fig. 7 is a top plan view of another example of a pedal assembly.

Figure 8 is a side plan view of the pedal assembly shown in figure 7.

Figure 8A is a cross-sectional view of the pedal assembly taken along line A-A in figure 8.

Like reference symbols in the various drawings indicate like elements.

Detailed Description

Referring now to the drawings and the exemplary embodiments described therein, a reinforced step assembly 10 is provided for a body structure or frame 102 of a vehicle 100, such as shown in fig. 1 and 2. The frame and associated step assemblies may have a variety of designs and configurations, such as for different styles and types of vehicles. For example, as shown in fig. 1, the vehicle 100 may operate, at least in part, a propulsion system of the vehicle with a battery, such as a traction battery or battery module, which may be supported in a battery tray 104 generally located between axles and near the floor of the vehicle 100 to distribute battery weight and establish a low center of gravity for the vehicle.

As shown, for example, in fig. 3-4B, the vehicle step assembly 10 includes a hollow outer structure 12 formed with an inner threshold member 14 and an outer threshold member 16, which may also be referred to as a step or section. The inner sill member 14 is longitudinally joined along the outer sill member 16 to define an elongated hollow space 18 between the inner and outer sill members 14, 16. The inner and outer threshold members 14, 16 forming the outer structure 12 surround an elongated hollow space 18 between the inner and outer threshold members 14, 16. The reinforcing inserts 20 are disposed in the hollow space 18 of the outer tread structure 12 and extend longitudinally along at least a portion or longitudinal section of the hollow space 18. The reinforcing insert 20 has a substantially uniform cross-sectional profile along its length, such as a tubular shape having one or more closed tubular cross-sections. Thus, the reinforcing insert 20 may be referred to as a tubular insert.

The reinforcement insert 20 is provided with one or more lateral compression control features to increase impact energy absorption by controlling lateral compression and deformation of the step assembly 10 that is subject to lateral impact forces transmitted to the outer threshold member, such as forces transmitted by a side rail impactor. For example, as shown in fig. 3-4A, crush grooves 22 are disposed along opposite upper and lower sides of the reinforcing insert 20. The crush grooves 22 are arranged to allow the reinforcing insert 20 to be laterally crushed like an accordion. This type of accordion extrusion can limit cracking and material failure by controlling how the section extrudes. The controlled compression provided by the compression grooves 22 also increases the material stack in later events, resulting in generally more energy absorption.

It is contemplated that the reinforcement inserts of the disclosed pedal assemblies may be incorporated into other types of structural beams, such as frames and structures of automobiles and other vehicles. Furthermore, the reinforcing inserts may be used with other structural frame components and impact energy management beams that are configured to withstand impact loads at various sections of the beam and absorb such impact loads in a desired manner. For example, as shown in fig. 2, the frame 102 of the vehicle 100 has a plurality of structural beams, one or all of which may be provided with internal reinforcements as described herein.

To form the outer structure 12, the inner threshold member 14 has an upper flange 14a connected along an upper flange 16a of the outer threshold member 16. The inner sill member 14 also has a lower flange 14b of the inner sill member 14 that is connected along a lower flange 16b of the outer sill member 16. This connection of the inner and outer sill members 14, 16 may be a direct contact engagement or may be an indirect connection through an intermediate, such as a flange, plate or bracket, sandwiched between the upper and lower flanges 14a, 14b, 16a, 16 b. As shown in fig. 3-4B, upper and lower flanges 14a, 14B, 16a, 16B are provided along the upper and lower edges of the inner and outer sill members 14, 16, respectively. The upper and lower flanges 14A, 14B, 16a, 16B are also substantially planar and oriented in a generally vertical configuration so as to be connected in direct contact along a portion of the length of the pedal assembly 10 (fig. 4A) and also indirectly at discrete portions in which the support bracket 62 is disposed between the flanges (fig. 4B). The upper and lower flanges 14a, 14b, 16a, 16b are joined together by welding, although in other examples of the step assembly, adhesives and/or mechanical fasteners may be used in addition to or in lieu of welding. The inner and outer threshold members 14, 16 shown in fig. 3 are steel, but it is contemplated that other examples may include alternative or multiple materials such as steel, aluminum, and/or composite materials.

The intermediate portions of the inner and outer sill members 14, 16 are generally disposed between the upper and lower flanges 14A, 14B, 16a, 16B and are shaped to have a generally concave cross-sectional shape, such as the exemplary C-shaped cross-section of the inner and outer side sill members 14, 16 shown in fig. 4A and 4B. The intermediate portion of the inner rocker member 14 has an upper wall section 24, an innermost wall section 26 and a lower wall section 28, each of which is generally planar in shape. Similarly, the middle portion of the outer threshold member 16 has an upper wall section 30, an outermost wall section 32, and a lower wall section 34, each of which is generally planar in shape. As shown in fig. 4A and 4B, the upper wall sections 24, 30 have a length substantially equal to the respective lower wall sections 26, 34. And the upper and lower wall sections 24, 26, 30, 34 are angled with respect to the horizontal, with each pair of upper and lower wall sections similarly angled. The upper and lower flanges 14A, 14B, 16a, 16B shown in fig. 4A and 4B are vertically aligned with each other due to the substantially equal length and angle. In other examples, such as shown in fig. 8A, the upper and lower flanges of the outer structure may be offset from one another. Moreover, the cross-sectional profiles of the inner and outer plates 14, 16 may be generally uniform along the length of the pedal assembly, such as shown in the examples shown in FIGS. 3-6, or may have some non-uniform features along the length, such as to accommodate jamb engagement, as shown in the examples of FIGS. 7 and 8.

As shown in fig. 3-4B, the reinforcing insert 20 is disposed within the elongated hollow space 18, extending longitudinally along the entire length of the inner threshold member 14 and along a portion of the length of the outer threshold member 16. In other examples, the reinforcement insert may extend along different longitudinal extents of the hollow outer structure, such as within or outside the length of the outer and inner threshold members. The crush-control features of the reinforcing insert 20 may be integrally formed in the reinforcing insert 20, such as crush grooves 22 that extend uniformly along the length of the reinforcing insert 20. As shown in fig. 4A and 4B, the extrusion groove 22 protrudes into the two tubular-shaped interior volumes 36 of the reinforcing insert 20. However, it is also contemplated that one or more crush grooves may extend outwardly away from the interior volume along the upper or lower wall of the reinforcing insert. Also, as shown in fig. 4A and 4B, crush grooves 22 are disposed on opposite sides of the interior volume 36 for side impact forces to laterally deform the reinforcing insert 20 inwardly at the crush grooves 22 to provide an accordion-type lateral crush mode. In other examples, a single crush groove may be provided, or additional crush grooves may be utilized. The crush grooves may be disposed at the upper and lower walls of the outer tubular section without crush grooves in the other tubular sections, or alternatively, the crush grooves may be disposed at the upper and lower walls of the inner tubular section without crush grooves in the outer tubular section, such as shown in fig. 8A.

In some examples, the crush groove is configured to deform simultaneously under a side impact force at the outer threshold member. For example, as shown in fig. 4A and 4B, the crush grooves 22 are disposed on opposite sides of the reinforcing insert in an aligned manner generally perpendicular to the direction of the horizontal side-to-side impact force. In this way, the crush grooves 22 can mirror image across the interior volumes of the outer and inner tubular sections to be vertically aligned with each other for optimizing the crush due to horizontal side impact forces. In other examples, the crush grooves may be arranged in laterally staggered alignment with each other, such as laterally staggered with each other across the enclosed interior volume, or staggered with crush grooves arranged at separate tubular sections of the reinforcing insert.

The reinforcing insert 20 has an upper wall 38 and a lower wall 40 that define opposite sides of the interior volume 36 of the reinforcing insert 20. As shown in fig. 4A and 4B, the upper wall 38 and the lower wall 40 of the reinforcing insert 20 are arranged in planar parallel alignment with each other. In other examples, the upper and lower walls may taper or angle toward or away from each other, or may have a non-planar shape, such as a curved or rounded transition along the width of the respective walls. The upper and lower walls 38, 40 of the reinforcing insert 20 each have a crush groove 22 that protrudes into the interior volume 36 and extends longitudinally along the respective upper and lower walls at opposite sides of the interior volume 36. Again, in other examples, one or more crush grooves may protrude outward from the interior volume. As also shown in fig. 4A and 4B, the reinforcing insert 20 includes an outer tubular section 42 and an inner tubular section 44 integrally formed together and disposed laterally adjacent to one another. The outer and inner tubular sections 42, 44 share a common central wall 46 that extends vertically between the upper and lower walls 38, 40 of the reinforcing insert 20 and that demarcates the internal volumes of the respective outer and inner tubular sections 42, 44.

As further shown in fig. 4A and 4B, the outer tubular section 42 of the reinforcing insert 20 has an outer wall 48 integrally interconnected between the upper wall 38 and the lower wall 40 of the reinforcing insert 20. The outer wall 48 faces the outermost wall section 32 of the outer threshold member 16 and contacts the outermost wall section 32. Similarly, the inner tubular section 44 has an inner wall 50 integrally interconnected between the upper wall 38 and the lower wall 40 of the reinforcing insert 20. The inner wall 50 faces the innermost wall section 26 of the inner threshold member 14 and contacts the innermost wall section 26. Thus, the reinforcing insert may have a lateral width between the inner and outer walls that is sized to closely fit or occupy the distance between the inner and outer sills, such as shown in fig. 4A and 4B. However, in other examples, the reinforcement insert may fit tightly to only one of the inner and outer sill members and have a gap on the other side, or alternatively may be designed with a gap on both sides so as to float in the space between the inner and outer sill members. Moreover, while the reinforcing inserts 20 are shown in fig. 4A and 4B as being spaced apart from the upper and lower wall sections 24, 30, 28, 34, it is contemplated that the spacing may be reduced or substantially eliminated due to the ability of the compression control features to cause inward deformation under lateral impact forces at the outside of the tread assembly, such as in an accordion shape within the exterior structure of the tread assembly.

To form the tubular insert 20 shown in fig. 3-4B, a sheet of metal is roll formed to have an outer tubular section 42 and an inner tubular section 44 laterally adjacent to each other, which share a common central wall 46. The outer sections of the metal plates forming the two adjacent tubular sections extend from opposite sides of the central section of the metal plates forming the common central wall 46. As oriented in fig. 3-4B, two adjacent tubular sections 14, 16 are defined on opposite sides of a common central wall 46 by upper walls 52, 54, lower walls 56, 58, outer wall 48, and inner wall 50. The extrusion groove 22 is roll formed into the sheet metal at the upper walls 52, 54 and lower walls 56, 58. The extrusion groove 22 has a width of about 10% -40% of the width of the corresponding wall section (or more preferably about 20% -30% of the width of the wall) and has a depth approximately equal to the width dimension. As shown in fig. 4A and 4B, the pressing groove 20 is shown as a semicircle. It is also contemplated that the depth and size of the extrusion grooves may be made shallower, deeper, wider, narrower, or otherwise modified to achieve the desired transverse extrusion characteristics.

The metal sheet used to form the reinforcing inserts in fig. 4A and 4B is a steel material, such as advanced high strength steel (AHHS), having a thickness of 0.8mm to 1.4mm or approximately between 1mm and 1.5 mm. Further, the plate 12 may have a tensile strength of about 800 to 2000MPa (i.e., about 120 to 290 ksi). It is also contemplated that the reinforcing inserts may be made of plates having different thicknesses, and may be made of one or a combination of different materials, such as steel, aluminum, and/or composite materials.

To maintain the roll-formed plate in the tubular shape of the reinforcing insert 20, one edge 60a of the plate is connected to the lower end of the central wall 46 by welding, and the other edge 60b is connected to the upper wall 52 near the upper end of the central wall 46 by welding. The upper walls 52, 54 and lower walls 56, 58 of adjacent tubular sections 42, 44 are substantially aligned with one another to form the respective upper and lower walls 38, 40 of the reinforcing insert. Further, the outer and inner walls 28, 30 are substantially parallel to each other and substantially perpendicular to the concentric wall 18 and to the upper and lower walls 20, 22, 24, 26. Additional examples of reinforcing inserts may take on various shapes and orientations from those shown in fig. 4A and 4B, and may include alternative dimensional proportions, for example for different applications of the inserts.

The reinforcing inserts may be supported and/or attached within the outer structure in various ways. For example, a series of brackets 62 (fig. 4B) are connected between the upper and lower flanges 14a, 14B, 16a, 16B of the outer and inner sill members 14, 16, which brackets are spaced apart along the length of the reinforcing inserts. As shown in fig. 4B, the bracket 62 has an L-shape with an inner portion 64 connected to the upper and lower walls 38, 40 and an outer portion 66 connected between the upper and lower flanges 14a, 14B, 16a, 16B by welding to support the reinforcing insert 20 in the hollow space 18. In other examples, the reinforcing insert may also or alternatively be connected to the inner surface of the outer or inner sill member, for example by welding, fasteners and/or adhesive.

Referring to fig. 5-6B, a reinforcement insert 120 is disposed within the hollow space 118, extending longitudinally along the entire inner threshold member 114 and along a portion of the outer threshold member 116. The crush groove 122 of the reinforcing insert 120 is integrally formed in the reinforcing insert 120 and extends uniformly along the length of the reinforcing insert 120. As shown in fig. 6A and 6B, the reinforcing insert 120 is longitudinally extruded, for example, with an aluminum alloy, to have an outer tubular section 142 and an inner tubular section 144 that share a common wall 146, the common wall 146 being integrally interconnected between the upper wall 138 and the lower wall 140 of the reinforcing insert 120. The upper wall 138 and the lower wall 140 are contiguous with opposite sides of the interior volume 136 of the reinforcing insert 120 and are disposed in planar parallel alignment with one another. The crush grooves 122 are crushed into the upper wall 138 and the lower wall 140 to extend into the corresponding tubular-shaped interior volume 136 of the reinforcing insert 120. The crush grooves 122 shown in fig. 6A and 6B have a V-shape to assist in initiating lateral crushing of the reinforcing insert at the crush grooves. The crush grooves 122 are disposed on opposite sides of the interior volume 136 for lateral impact forces to deform the reinforcing insert 120 laterally inward at the crush grooves 122, thereby providing an accordion-type lateral crush mode.

As shown in fig. 6A and 6B, the reinforcing insert 120 includes an outer tubular section 142 and an inner tubular section 144 integrally formed together and disposed laterally adjacent to one another. The crush grooves 122 mirror the interior volume 136 of the outer tubular section 142 and the inner tubular section 144 to be vertically aligned with each other. As also shown in fig. 6A and 6B, the outer tubular section 142 of the reinforcing insert 120 has an outer wall 148 integrally interconnected between the upper wall 138 and the lower wall 140 of the reinforcing insert 120. The outer wall 148 faces the outermost wall section 132 of the outer threshold member 116 and contacts the outermost wall section 132. Similarly, the inner tubular section 144 has an inner wall 150 integrally interconnected between the upper wall 138 and the lower wall 140 of the reinforcing insert 120. The inner wall 150 faces the innermost wall section 126 of the inner threshold member 114 and contacts the innermost wall section 126.

To support the reinforcement insert 120 within the outer structure 112, a series of brackets 162 are attached between the upper and lower flanges 114a, 114b, 116a, 116b of the outer and inner threshold members 114, 116. As shown in fig. 6B, bracket 162 has an L-shape with an inner portion 164 connected to upper wall 138 and lower wall 140 and an outer portion 166 connected between upper and lower flanges 114a, 114B, 116a, 116B to support reinforcing insert 120 in hollow space 118. The connection of the brackets to the reinforcing inserts and the external structure may be accomplished using welds, fasteners, adhesives and/or material intermediates, for example, in a manner that prevents galvanic corrosion.

Further, in some embodiments, the reinforcement insert may include a flange attached between the upper flanges of the outer and inner threshold members, wherein the flange is attached to the outer structure of the step assembly to support the tubular insert in the hollow space of the outer structure. As shown in fig. 8A, the reinforcing insert 220 includes an upper flange portion 270 extending generally upwardly from the crushable insert portion 268, and a lower flange portion 272 extending generally downwardly from the crushable insert portion 268. The upper and lower flange portions 270, 272 are attached between the respective upper and lower flanges 214a, 214b, 216a, 216b between the edges of the inner and outer sill members 214, 216 or the flanges of the panels 212, 214 to secure the reinforcing insert 220 relative to the inner and outer sill members 214, 216. For example, the flange portions are spot welded between the first and second panels 214, 216, although alternative welding methods or different attachment means, such as adhesives, mechanical fasteners, or combinations thereof, may be used. In other embodiments, the integral flange of the reinforcing insert may also be used for attachment to a vehicle frame or other component part.

With further reference to fig. 7-8A, the reinforcing insert 220 is roll formed from sheet metal to provide the squeezable insert portion 268 and the upper and lower flange portions 270, 272 as integral parts of the sheet metal to extend continuously longitudinally along the length of the reinforcing insert 220. The upper flange portion 270 and the lower flange portion 272 of the reinforcing insert 220 are provided at edge portions of the metal plate. As shown in fig. 8A, the wall sections of the extrudable insert portion 268 include a common central wall 246 dividing two adjacent tubular sections 214, 216, upper walls 252, 254, lower walls 256, 258, outer wall 248 and inner wall 250. The extrusion groove 222 is roll formed into the sheet metal at the upper walls 252, 254 and the lower walls 256, 258. After forming welds along the upper and lower walls to close the adjacent tubular sections 242, 244, an upper flange portion 270 extends upwardly from the upper wall 254 and a lower flange portion 272 extends downwardly from the lower wall 256.

As further shown in fig. 8A, the middle portion of the outer threshold member 216 has an upper wall section 230 formed in a stepped shape and integrally interconnected with a generally planar and vertically oriented outermost wall section 232. The outermost wall section 232 extends downwardly to integrally interconnect with a generally planar lower wall section 234 that is slightly angled from horizontal. The stepped shape of the upper wall section 230 reduces the distance that passes through the hollow interior 218 between the inner and outer sill members 214, 216 at the upper portion of the inner sill member 214.

Also for purposes of this disclosure, 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 in addition to the explicitly specified 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. Accordingly, specific dimensions and other physical characteristics related to the embodiments disclosed herein are not to be considered as limiting.

Changes and modifications can be made to the specifically described embodiments without departing from the principles of the present invention, which is limited only by the scope of the appended claims as interpreted according to the principles of patent law. The present 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 present disclosure may be practiced otherwise than as specifically described.

Claims (35)

1. A vehicle pedal assembly comprising:

an outer threshold member;

an inner threshold member longitudinally attached along the outer threshold member to define a hollow space between the inner and outer threshold members; and

a tubular insert disposed in and extending longitudinally along the hollow space, the tubular insert having upper and lower walls defining opposite sides of an interior volume of the tubular insert,

wherein at least one of the upper wall or the lower wall of the tubular insert has a crush groove extending longitudinally along the tubular insert, and

wherein the tubular insert is configured for inducing a lateral deformation of the tubular insert at the crush recess against a lateral impact force at the outer threshold member.

2. The vehicle pedal assembly of claim 1 wherein the crush groove protrudes into the interior volume of the tubular insert.

3. The vehicle step assembly of claim 1 wherein the upper wall and the lower wall each include the crush groove disposed along the respective upper wall and lower wall at opposite sides of the interior volume.

4. The vehicle pedal assembly of claim 3 wherein the crush recess is vertically aligned across the interior volume of the tubular insert.

5. A vehicle pedal assembly as set forth in claim 3 wherein said upper wall and said lower wall of said tubular insert are disposed in planar parallel alignment with one another.

6. The vehicle pedal assembly of claim 1 wherein the tubular insert includes an outer tubular section and an inner tubular section integrally formed together and disposed laterally adjacent to one another.

7. The vehicle pedal assembly of claim 6 wherein the outer tubular section and the inner tubular section share a common central wall extending vertically between the upper wall and the lower wall of the tubular insert.

8. The vehicle step assembly of claim 6, wherein the outer tubular section includes an outer wall attached at the outer threshold member.

9. The vehicle pedal assembly of claim 6 wherein the inner tubular section and the outer tubular section each include crush grooves disposed along respective upper and lower walls of the inner and outer tubular sections.

10. The vehicle pedal assembly of claim 1 wherein the tubular insert comprises a metal plate integrally formed to have an outer tubular section, an inner tubular section, and crush grooves disposed in the outer tubular section and the inner tubular section.

11. A vehicle pedal assembly comprising:

a rocker structure having an outer rocker member attached along an inner rocker member;

a reinforcement insert disposed in the hollow interior between the outer and inner sill members, the reinforcement insert comprising an outer tubular section and an inner tubular section integrally formed together and disposed laterally adjacent to each other; and

an extrusion control feature integrally disposed at a wall of the reinforcing insert and extending longitudinally along a length of the reinforcing insert,

wherein the crush control feature is configured to laterally deform the reinforcement insert in an accordion-type crush manner against a side impact force at the outer threshold member.

12. The vehicle pedal assembly of claim 11 wherein the outer tubular section and the inner tubular section share a common central wall of the reinforcement insert that extends vertically between an upper wall and a lower wall of the reinforcement insert.

13. The vehicle pedal assembly of claim 12 wherein the crush control feature includes a first crush groove disposed at the upper wall of the reinforcement insert and a second crush groove disposed at the lower wall of the reinforcement insert.

14. The vehicle pedal assembly of claim 13 wherein the first and second crush grooves are mirrored over an interior volume of the reinforcement insert.

15. The vehicle pedal assembly of claim 11 wherein the reinforcement insert comprises a metal plate integrally formed to have the outer and inner tubular sections and the crush control feature disposed therein.

16. The vehicle pedal assembly of claim 11 wherein the tubular insert is longitudinally extruded to form the outer and inner tubular sections and the extrusion control feature as a single unitary piece.

17. The vehicle step assembly of claim 11, wherein the tubular insert is secured at an inner surface of the rocker structure by at least one of welding, fasteners, or adhesive.

18. A vehicle pedal assembly comprising:

an outer threshold member;

an inner threshold member longitudinally attached along the outer threshold member to define a hollow space between the inner and outer threshold members; and

a tubular insert arranged in and extending longitudinally along the hollow space, the tubular insert comprising an outer tubular section and an inner tubular section integrally formed together and arranged laterally adjacent to each other,

wherein at least one of the outer tubular section or the inner tubular section comprises upper and lower crush grooves arranged at the upper and lower walls of the respective outer or inner tubular section,

wherein the upper and lower crush grooves extend longitudinally along the tubular insert and are configured for inducing lateral deformation of the tubular insert against a lateral impact force at the outer threshold member.

19. The vehicle pedal assembly of claim 18 wherein the upper crush groove and the lower crush groove are vertically aligned on the respective outer tubular section and the inner tubular section of the tubular insert.

20. The vehicle pedal assembly of claim 18 wherein the upper wall and the lower wall of the tubular insert are arranged in planar parallel alignment with each other and wherein the outer tubular section and the inner tubular section share a common central wall extending vertically between the upper wall and the lower wall of the tubular insert.

21. A vehicle pedal assembly comprising:

an outer threshold member;

an inner threshold member longitudinally attached along the outer threshold member to define a hollow space along and between the inner and outer threshold members;

a tubular insert disposed in and extending longitudinally along the hollow space, the tubular insert having upper and lower walls defining opposite sides of an interior volume of the tubular insert; and

wherein at least one of the upper or lower walls of the tubular insert has a crush groove extending longitudinally along the tubular insert, the tubular insert being configured for lateral impact forces at the outer threshold member to laterally deform the tubular insert at the crush groove to provide accordion-like lateral compression to at least partially absorb the lateral impact forces.

22. The vehicle pedal assembly of claim 21 wherein the crush groove protrudes into the interior volume of the tubular insert.

23. The vehicle step assembly of claim 21, wherein a pair of crush grooves are disposed along the respective upper and lower walls at opposite sides of the interior volume.

24. The vehicle pedal assembly of claim 23 wherein the pair of crush grooves are mirrored across the interior volume.

25. The vehicle pedal assembly of claim 23 wherein the crush recess is vertically aligned across the interior volume of the tubular insert.

26. The vehicle step assembly of claim 21, wherein the crush recess of the tubular insert is configured to deform simultaneously under the side impact force at the outer threshold member.

27. The vehicle step assembly of claim 23, wherein the upper wall and the lower wall of the tubular insert are disposed in planar parallel alignment with each other and spaced apart from the outer and inner threshold members.

28. The vehicle pedal assembly of claim 21 wherein the tubular insert includes an outer tubular section and an inner tubular section integrally formed together and disposed laterally adjacent to one another.

29. The vehicle pedal assembly of claim 28 wherein the outer tubular section and the inner tubular section share a common central wall extending vertically between the upper wall and the lower wall of the tubular insert.

30. The vehicle step assembly of claim 21, wherein the tubular insert includes an outer tubular section having an outer wall facing the outer threshold member and integrally interconnected between the upper wall and the lower wall of the tubular insert.

31. The vehicle step assembly of claim 21, further comprising a bracket attached between the outer and inner threshold members upper flanges, the bracket attached to the tubular insert and supporting the tubular insert in the hollow space.

32. The vehicle step assembly of claim 21, wherein the tubular insert includes a flange attached between the outer and inner threshold members upper flanges, the flange supporting the tubular insert in the hollow space.

33. The vehicle step assembly of claim 21, wherein the tubular insert is secured at an inner surface of the outer threshold member or the inner threshold member by at least one of welding, fasteners, or adhesive.

34. The vehicle pedal assembly of claim 21 wherein the tubular insert comprises a metal plate having an outer tubular section and an inner tubular section with a common central wall, the outer tubular section and the inner tubular section being disposed laterally adjacent to one another.

35. The vehicle pedal assembly of claim 21 wherein the tubular insert is longitudinally extruded having an outer tubular section and an inner tubular section that share a common wall integrally interconnected with the upper and lower walls of the tubular insert.