Shape Corporation

Brian Oxley

Thomas J Johnson

Brian Malkowski

Joseph R Matecki

Matthew Kuipers

Daniel Gatti

Doug Witte

Douglas S Baas

Cody Alger

Ed C Pendergrass

Kannan Ramamoorthy

Thomas Johnson

A vehicle rocker assembly includes a sill inner and a sill outer. An upper flange portion of the sill inner is coupled with an upper flange portion of the sill outer, and a lower flange portion of the sill inner is coupled with a lower flange portion of the sill outer to enclose a hollow interior of the vehicle rocker assembly. One of the sill inner or the sill outer includes a reinforcement structure integrated in the sill wall of the respective still inner or sill outer. The reinforcement structure includes walls that each laterally span the hollow interior and form a multi-hollow cross-sectional shape with the sill inner and sill outer.

Vehicle rocker assembly

A rocker component for a vehicle having a reinforcement beam including a metal sheet that is shaped with a plurality of elongated bends extending in parallel along a length of the reinforcement beam that together form a cross-sectional shape extending continuously along the length of the reinforcement beam. The cross-sectional shape of the reinforcement beam includes a beam portion and a flange portion integrally extending from the beam portion and includes an edge of the metal sheet. The rocker component also includes a sill panel having flanges extending longitudinally along upper and lower edges of the sill panel relative to the vehicle, the flange portion of the reinforcement beam joined to one of the flanges of the sill panel to secure the reinforcement beam to the sill panel in replacement of a separate second sill panel.

Vehicle rocker component

A rocker component for a vehicle includes a reinforcement beam having a metal sheet that is shaped with a plurality of elongated bends extending in parallel along a length of the reinforcement beam that together form a cross-sectional shape extending continuously along the length of the reinforcement beam. The cross-sectional shape of reinforcement beam includes a beam portion and a flange portion integrally extending from the beam portion. The beam portion has a multi-hollow shape that encloses a plurality of hollow cavities that extend longitudinally between openings at opposing ends of the reinforcement beam. The flange portion integrally extends from the beam portion and includes an edge of the metal sheet. The flange portion is configured to attach to the vehicle for supporting the rocker component along an outboard side region of the vehicle.

Vehicle component with multi-hollow beam

A vehicle reinforcement beam is roll formed from a metal sheet to provide a multi-tubular reinforcement beam that includes two adjacent tubular sections that share a common center wall. The outer sections the metal sheet extend from opposing ends of the common center wall and are formed to enclose the adjacent tubular sections. An edge portion of the metal sheet that is bent to have a bend radius of about 3-9 mm, where the edge portions attach in abutting and continuous contact with the common center wall to form crevices between the adjacent tubular sections along the first and second faces. A weld is formed in each of the crevices to define crevice ribs in general alignment with and at each of the opposing first and second ends of the common center wall that are configured to improve bending strength and torsional strength of the reinforcement beam.

Multi-tubular reinforcement beam with center leg

A reinforcement beam is roll formed from a metal sheet for use in a vehicle bumper system. The reinforcement beam includes adjacent tubes having a common center wall and lateral portions extending from opposing sides of the common center wall that are roll formed simultaneously in the same rotational direction to enclose interior volumes of the adjacent tubes and to define top and bottom walls and front and rear wall of the reinforcement beam. The front walls of the adjacent tubes each include a channel rib depressed into the interior volume of the respective adjacent tube longitudinally along the reinforcement beam for stiffening the respective front wall. A weld is formed separately in each of the seams between the front walls and between the rear walls, thereby defining a crevice rib between the channel ribs to improve the bending strength and torsional strength of the reinforcement beam.

Tubular beam with center leg and method for forming the same

A bumper reinforcement beam includes a beam having a length and mounts at ends of the beam and cross sectional shapes at various locations along the length, including a first cross sectional shape near ends of the beam providing a first bending moment and a second cross sectional shape at a center of the beam providing a second bending moment different than the first bending moment, and further including intermediate cross sectional shapes between the ends and center having intermediate bending moments between the first and second bending moments. The cross sections may define open C-shapes or may include a tubular shape.

Bumper reinforcement beam with varied bending moment

The specification discloses automotive body components including roll-formed components and slip-plane brackets. The roll-formed components may be used in place of components manufactured using other techniques, such as hydroforming. The slip-plane brackets may be adjustably positioned on the roll-formed components. More specifically, the slip-plane brackets are adjustable in two or more dimensions (e.g. laterally and longitudinally) before attachment, so that the brackets may compensate for tolerances in the roll-formed components. Attachment techniques may include welding and/or adhering.

Automotive body components and assemblies

A structural beam includes a reinforcement beam having a length and mounts at ends of the beam and cross sectional shapes at various locations along the length, including a first cross sectional shape near ends of the beam providing a first bending moment and a second cross sectional shape at a center of the beam providing a second bending moment different than the first bending moment, and further including intermediate cross sectional shapes between the ends and center having intermediate bending moments between the first and second bending moments. The cross sections may define open C-shapes or may include a tubular shape.

Beam with varied bending moment, apparatus, and method

An apparatus forms a sheet into a beam having four exterior walls and a common center leg extending between an opposing two of the walls. The apparatus includes a roll former forming the sheet into the beam cross section, a welding station with top and bottom laser welders, and a weld box fixture having inwardly-biased external mandrels (biased by actuators) and outwardly-biased internal split mandrels (biased by springs) that interact to hold a desired shape of the beam in the weld fixture, and also includes a sweeping unit and cutoff device. By this arrangement, the internal and external mandrels, in combination with a bias of the actuators and springs, control a shape of the beam by flexure and movement of material of the sheet when in the weld box fixture during a welding process of the welder.

Apparatus for making tubular beam with center leg

A roll former for forming a sheet into a continuous multi-tubular reinforcement beam. The roll former includes a first set of rollers that are configured to bend the sheet to form a common center wall in generally perpendicular orientation relative to first and second lateral portions of the sheet that extend in opposing directions from respective first and second radiused ends of the common center wall. The first set of rollers also form radiused edges on the first and second lateral portions. A second set of rollers is configured to form a channel rib longitudinally along each of the first and second lateral portions. A third set of rollers is configured to bend the first and second lateral portions simultaneously and equally to abut the first and second radiused edges with the respective first and second radiused ends of the common center wall to define adjacent tubes of the beam.

Growing community of inventors

Ada, MI, United States of America

Brian Oxley