IP Library Granted Patent US 12668202
Granted Patent B2
US 12668202 · App. 18/064,768 · Granted Jun 30, 2026

Beam assembly with multi-hollow formation

Inventor: Ed Pendergrass (West Olive, MI)
Assignee: Shape Corp.
B60R19/18B21C37/0803B21D53/88B60R2019/1806
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Quick Facts
Patent No.
US 12668202
App. No.
18/064,768
Granted
Jun 30, 2026
Kind
B2
Abstract

A beam assembly includes a first beam that has a first tubular portion and a first projecting portion that extends from the first tubular portion. A second beam has a second tubular portion and a second projecting portion that extends from the second tubular portion. The elongated interior of the first tubular portion defines a first hollow area and the elongated interior of the second tubular portion defines a second hollow area. The first beam is attached to the second beam with the first projecting portion attached to the second tubular portion and the second projecting portion attached to the first tubular portion to define a third hollow area between the first and second projecting portions.

Claims (32)

1 . A beam assembly comprising:

a first beam comprising a first metal sheet, the first metal sheet forming an enclosed portion and a remaining portion of the first metal sheet extending along the enclosed portion of the first beam; and

a second beam having a second metal sheet, the second metal sheet forming an enclosed portion, wherein the first beam is attached to the second beam with the remaining portion of the first metal sheet attached to the enclosed portion of the second beam to define a hollow area between the first and second beams,

wherein the remaining portion of the first metal sheet is disposed over a wall section of the enclosed portion of the second beam and includes a distal end that extends away from the enclosed portion of the second beam at an inset location from the wall section to provide a flange.

2 . The beam assembly of claim 1 , wherein the second beam comprises a projecting portion extending along the enclosed portion of the second beam.

3 . The beam assembly of claim 2 , wherein the projecting portion of the second beam is attached to the enclosed portion of the first beam.

4 . The beam assembly of claim 1 , wherein the wall section of the enclosed portion of the first beam comprises a planar section.

5 . The beam assembly of claim 1 , wherein the first beam and the second beam each comprise a same cross-sectional shape.

6 . The beam assembly of claim 1 , wherein the first beam comprises a P-shaped transverse cross section.

7 . The beam assembly of claim 6 , wherein the P-shaped transverse cross section extends continuously along a length of the first beam.

8 . The beam assembly of claim 1 , wherein the first and second beams are attached together via welding.

9 . The beam assembly of claim 1 , wherein the enclosed portion of the first beam comprises at least three substantially planar wall sections, and wherein the remaining portion of the first metal sheet extends from the enclosed portion of the first beam in planar parallel alignment with one of the wall sections.

10 . The beam assembly of claim 1 , wherein the enclosed portion of the first beam has a seam disposed along a length of the first beam, the seam defined by an edge section of the first metal sheet attached along an intermediate section of the first metal sheet, and wherein the remaining portion of the first metal sheet protrudes at the seam from the intermediate section of the first metal sheet.

11 . A beam assembly comprising:

a first beam comprising a first metal sheet that forms a first enclosed portion and a first projecting portion extending along the first enclosed portion; and

a second beam comprising a second metal sheet that forms a second enclosed portion and a second projecting portion extending along the second tubular portion,

wherein the first beam is attached to the second beam with the first projecting portion attached to the second enclosed portion and the second projecting portion attached to the first enclosed portion to define a hollow area surrounded by the first and second enclosed portions and the first and second projecting portions, and

wherein the first projecting portion of the first beam is partially disposed over and partially extends away from the second enclosed portion of the second beam to provide a first flange inset from an outer wall section of the second enclosed portion.

12 . The beam assembly of claim 11 , wherein a cross-sectional shape of each of the first beam and the second beam taken transverse to lengths of the first and second beams comprises a P-shape.

13 . The beam assembly of claim 11 , wherein a cross-sectional shape of the first beam and the second beam taken transverse to lengths of the first and second beams extend continuously along the respective lengths.

14 . The beam assembly of claim 11 , wherein the first and second beams are attached together via welding.

15 . The beam assembly of claim 11 , wherein the second projecting portion of the second beam is disposed over and extends beyond the first enclosed portion of the first beam to provide a second flange.

16 . The beam assembly of claim 11 , wherein the first enclosed portion comprises at least three substantially planar wall sections, and wherein the first projecting portion of the first metal sheet extends from the first enclosed portion in parallel alignment with one of the at least three substantially planar wall sections.

17 . The beam assembly of claim 11 , wherein the first flange is disposed in a first plane, the first projecting portion is disposed in a second plane, and the first plane is parallel to the second plane.

18 . The beam assembly of claim 11 , wherein the first enclosed portion has a seam disposed along a length of the first enclosed portion, the seam defined by an edge section of the first metal sheet attached along an intermediate section of the first metal sheet, and wherein the first projecting portion of the first metal sheet protrudes at the seam from the intermediate section of the first metal sheet.

19 . A beam assembly comprising:

a first beam comprising a first metal sheet, the first metal sheet forming a first enclosed portion and a first projecting portion extending along the first enclosed portion; and

a second beam having a second metal sheet, the second metal sheet forming a second enclosed portion and a second projecting portion extending along the second enclosed portion,

wherein the first beam is attached to the second beam with the first projecting portion of the first beam attached to the second enclosed portion of the second beam and the second projecting portion of the second beam attached to the first enclosed portion of the first beam to define a hollow area between the first and second beams,

wherein the first projecting portion of the first beam is partially disposed over and partially extends away from the second enclosed portion of the second beam at an inset location between opposing outer walls of the second enclosed portion to provide a first flange.

20 . The beam assembly of claim 19 , wherein the first enclosed portion has a first seam disposed along a length of the first enclosed portion, the first seam defined by an edge section of the first metal sheet attached along an intermediate section of the first metal sheet, wherein the second enclosed portion has a second seam disposed along a length of the second enclosed portion, the second seam defined by an edge section of the second metal sheet attached along an intermediate section of the second metal sheet, and wherein the second projecting portion of the second beam is disposed over and extends beyond the first enclosed portion of the first beam to provide a second flange.

21 . The beam assembly of claim 19 , wherein the first flange is disposed in a first plane, the first projecting portion is disposed in a second plane, and wherein the first plane is parallel to the second plane.