Vehicle front rail

1 . A front rail for a vehicle frame, the front rail comprising:

a tubular beam formed from a single, high-strength metal sheet to define a closed cross-sectional shape that extends along a length of the tubular beam;

wherein the tubular beam has a front end configured to couple with a bumper assembly and a rear end opposite the front end and configured to couple to a mid-frame component;

wherein the closed cross-sectional shape of the tubular beam includes a first side wall, a second side wall, a top wall, a bottom wall, and a central wall extending between the first and second side walls to separate two hollow channels within the closed cross-sectional shape;

wherein the central wall, the first side wall, the second side wall, the top wall, and the bottom wall are together formed by the single, high-strength metal sheet; and

wherein the closed cross-sectional shape is configured to undergo axial loading in a frontal vehicle impact between the front and rear ends.

2 . The front rail of claim 1 , wherein the two hollow channels extend longitudinally and continuously along the length of the tubular beam.

3 . The front rail of claim 1 , wherein the central wall is integrally connected to at least one of the first side wall or the second side wall.

4 . The front rail of claim 3 , wherein the first side wall of the tubular beam includes a recessed area that extends along the length of the tubular beam.

5 . The front rail of claim 1 , wherein the central wall extends from a first vertical location at the first side wall to a second vertical location at the second side wall, and wherein the first vertical location is lower than the second vertical location.

6 . The front rail of claim 1 , wherein the closed cross-sectional shape comprises a groove protruding inward of the closed cross-sectional shape and extending longitudinally in a groove direction, wherein the groove direction is substantially parallel the length of the tubular beam.

7 . The front rail of claim 1 , wherein the first side wall is a seamless wall formed by the single, high-strength metal sheet.

8 . The front rail of claim 1 , wherein a first edge and a second edge of the single, high-strength metal sheet are secured respectively at a first joint location at the first side wall and a second joint location at the second side wall.

9 . A structural beam for a vehicle, the structural beam comprising:

an elongated body formed from a single metal sheet and configured to extend from a first end at a bumper assembly to a second end at a mid-frame assembly, the elongated body having a cross-sectional shape that extends a length of the elongated body;

wherein the cross-sectional shape of the elongated body includes a first side wall, a second side wall, a top wall, a bottom wall, and a central wall extending between the first and second side walls,

wherein the elongated body includes two hollow channels divided by the central wall formed by the single metal sheet, and

wherein the central wall, the first side wall, the second side wall, the top wall, and the bottom wall are together formed by the single metal sheet.

10 . The structural beam of claim 9 , wherein the second side wall forms an outer wall of the elongated body and includes a plurality of grooves protruding inwardly of the cross-sectional shape and extending longitudinally along a portion of the length of the elongated body.

11 . The structural beam of claim 10 , wherein the plurality of grooves are located adjacent to a bend initiator that are together configured to initiate a bending of the elongated body upon axial loading of the structural beam.

12 . The structural beam of claim 9 , wherein the central wall extends from a first vertical location at the first side wall to a second vertical location at the second side wall, and wherein the first vertical location is lower than the second vertical location.

13 . The structural beam of claim 12 , wherein a fastener is disposed at the first side wall at a central location vertically between the first and second vertical locations.

14 . The structural beam of claim 9 , wherein the single metal sheet comprises a high strength steel.

15 . The structural beam of claim 12 , further comprising:

a first recessed area disposed at the first side wall and a second recessed area disposed at the second side wall;

a first edge portion and a second edge portion of the single metal sheet; and

wherein the first edge portion is positioned in the first recessed area and the second edge portion is positioned in the second recessed area, wherein the first and second side walls of the elongated body are disposed in generally parallel alignment.

16 . The structural beam of claim 15 , wherein a first weld joint is formed between the first edge portion and the first recessed area, and a second weld joint is formed between the second edge portion and the second recessed area.

17 . The structural beam of claim 9 , wherein the central wall includes a stepped shape including a first horizontal portion, a second horizontal portion, and a vertical portion attached to the first horizontal portion and the second horizontal portion.

18 . The structural beam of claim 17 , further comprising a plurality of fasteners on an inner wall of the elongated body, wherein at least a pair of fasteners are laterally aligned with the vertical portion of the central wall.

19 . A front rail configured to be supported by a vehicle frame, the front rail comprising:

a tubular body formed by a single, high-strength metal sheet and defining a cross-sectional shape along a length of the tubular body;

wherein the cross-sectional shape includes a first side wall, a second side wall, a top wall, a bottom wall, and a central wall extending from the first side wall to the second side wall of the tubular body defining a first longitudinal hollow channel and a second longitudinal hollow channel on opposing sides of the central wall;

wherein a groove is disposed in the first side wall of the tubular body and extending longitudinally in the length of the tubular body; and

wherein the tubular body is configured to undergo axial loading during a frontal vehicle impact.

20 . The front rail of claim 19 , wherein, under axial loading, the tubular body is configured to bend at an end of the groove.