# US 2025/0282425 A1 · Vehicle structural component with exterior stiffening channels > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2025/0282425 A1 - Document ID: US20250282425A1 - Status: Published application - Kind: A1 - Application number: 19/076,734 - Filed: 2025-03-11 - Published: 2025-09-11 - Earliest claimed: 2024-03-11 - Assignees: Shape Corp. - Applicants: Shape Corp. - Inventors: Matthew Kuipers - Web page: https://patentgrep.com/patent/US20250282425A1 ## CPC - B62D 25/025: {Side sills thereof} - B62D 21/157: {for side impacts} - B62D 29/008: {predominantly of light alloys, e.g. extruded} - B62D: MOTOR VEHICLES; TRAILERS (steering, or guiding on a desired track, of agricultural machines or implements A01B69/00; wheels, castors, axles, increasing wheel adhesion B60B; vehicle tyres, tyre inflation or tyre changing B60C; connections between vehicles of a train or the like B60D; vehicles for use on rail and road, amphibious or convertible vehicles B60F; suspension arrangements B60G; heating, cooling, ventilating or other air treating devices B60H; windows, windscreens, non-fixed roofs, doors or similar devices, protective coverings for vehicles not in use B60J; propulsion plant arrangements, auxiliary drives, transmissions, controls, instrumentation or dashboards B60K; electric equipment or propulsion of electrically-propelled vehicles B60L; power supply for electrically-propelled vehicles B60M; passenger accommodation not otherwise provided for B60N; adaptations for load transportation or to carry special loads or objects B60P; arrangement of signalling or lighting devices, the mounting or supporting thereof or circuits therefor, for vehicles in general B60Q; vehicles, vehicle fittings or vehicle parts not otherwise provided for B60R; servicing, cleaning, repairing, supporting, lifting, or manoeuvring, not otherwise provided for, B60S; brake arrangements, brake control systems or parts thereof B60T; air-cushion vehicles B60V; motor-cycles, accessories therefor B62J, B62K; testing of vehicles G01M) ## Abstract 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. ## Claims ### Claim 1 A structural component of a vehicle, the structural component comprising: an elongated beam having a seamless outer wall surrounding a hollow interior area along a length of the elongated beam, the outer wall defining a closed cross-sectional shape along the length of the elongated beam, wherein the outer wall of the elongated beam includes a plurality of channels that protrude into the hollow interior area and extend laterally in a direction between an inboard side and an outboard side of the elongated beam. ### Claim 2 (depends on 1) The structural component of claim 1, wherein the elongated beam is comprised of an extruded aluminum. ### Claim 3 (depends on 2) The structural component of claim 2, wherein the plurality of channels are formed in at least one surface of the elongated beam after extrusion. ### Claim 4 (depends on 1) The structural component of claim 1, wherein the plurality of channels extend across at least one section of the outer wall, and the outer wall includes a flat surface spanning between each of the plurality of channels. ### Claim 5 (depends on 1) The structural component of claim 1, wherein the closed cross-sectional shape tapers at least partially towards the outboard side. ### Claim 6 (depends on 5) The structural component of claim 5, wherein the outer wall of the elongated beam includes an upper wall section, a lower wall section, an inboard side wall section extending between the upper wall section and the lower wall section, an upper angled wall section extending outboard at a downward angle from the upper wall section, a lower angled wall section extending outboard at an upward angle from the lower wall section, and an outboard side wall section extending between the upper angled wall section and the lower angled wall section. ### Claim 7 (depends on 1) The structural component of claim 1, wherein each of the plurality of channels includes a pair of ridges and a furrow, the pair of ridges located on either side of the furrow, and where the channel begins to extend inward from the flat surface. ### Claim 8 (depends on 7) The structural component of claim 7, wherein the furrow is located at the most inward portion of the channel. ### Claim 9 (depends on 8) The structural component of claim 8, wherein a depth of the channel is defined by a length from the ridge to the furrow, and wherein the depth of the channel is shorter in length than a length of the flat surface between adjacent channels. ### Claim 10 (depends on 1) The structural component of claim 1, wherein the plurality of channels have a U-shape. ### Claim 11 A vehicle rocker assembly, comprising: an inner sill; an outer sill; and a rocker insert comprising a structural beam comprising at least four wall sections defining a closed cross-sectional shape along a length of the structural beam and a channeled portion located on at least one of the four wall sections, wherein the channeled portion includes a plurality of channels extending laterally over the width of the at least one wall section. ### Claim 12 (depends on 11) The vehicle rocker assembly of claim 11, wherein the structural beam is comprised of extruded aluminum. ### Claim 13 (depends on 11) The vehicle rocker assembly of claim 11, wherein the structural beam includes a seamless outer wall that comprises the four wall sections. ### Claim 14 (depends on 13) The vehicle rocker assembly of claim 13, wherein the structural beam includes an inner wall that extends between two of the four wall sections along the length of the structural beam. ### Claim 15 (depends on 13) The vehicle rocker assembly of claim 13, wherein the outer wall includes six wall sections that form a tapered cross-sectional shape. ### Claim 16 (depends on 11) The vehicle rocker assembly of claim 11, wherein the plurality of channels extend inward into the cross-sectional shape and comprise a U-shape. ### Claim 17 (depends on 11) The vehicle rocker assembly of claim 11, wherein the plurality of channels are oriented to extend linearly and in parallel alignment with each other and to extend laterally between the inner sill and the outer sill. ### Claim 18 (depends on 11) The vehicle rocker assembly of claim 11, wherein the cross-sectional shape of the rocker insert includes a plurality of passages defined by a plurality of interior walls extending the length of the rocker insert. ### Claim 19 (depends on 11) The vehicle rocker assembly of claim 11, wherein the structural beam includes an upper wall section, a lower wall section, an outboard side wall section, and an inboard side wall section, and wherein the channeled portion extends along the width of both the upper wall section and the lower wall section.