Ford Global Technolgoies, LLC

Lou Ratsos

David Anthony Wagner

Xiaoming Chen

John T Reed

Daniel Szalay

Hikmat F Mahmood

James Wayne Lowe

Gregory S Frederick

Dean A Gericke

Lawrence Anderson Queener

Ramakrishna P Koganti

Sergio Angotti

Frank J Day

Bryan Mikula

David Wagner

A hydroforming process forms a hydroformed automotive component as a multiple cell member having an integral internal rib separating the cells and reinforcing the hydroformed component to increase the strength of a hydroformed component with a given size and shape. The tubular blank can be manufactured through a roll-forming process or by welding two structural tubular members, to form a tubular blank that has multiple cells with an internal rib separating the cells. The hydroforming process injects fluid under pressure into each of the cells to expand the tubular blank into the shape defined by the die holding the blank. The internal web separating the cells of the blank becomes an integral internal reinforcement spanning the component to enhance the strength, rigidity and stiffness of the component. Providing differential pressure on the multiple cells can stretch and twist the internal rib for positioning internally as desired.

Double hydroformed tube with integral reinforcement

A striker reinforcement plate is configured for installation into the interior of a closed section, hydroformed tubular automotive frame member. The striker reinforcement plate is formed with an enlarged mounting tab at one end and a weld tab at the opposing end. The striker reinforcement plate is inserted through a slot formed into the wall of the tubular frame member, against which the enlarged mounting tab prevents the striker reinforcement plate from falling through the slot, and the weld tab is inserted through a special formed opening to receive the weld tab. The weld tab can then be welded to the exterior surface of the tubular frame member, which combined with the enlarged mounting tab secured against the slot holds the striker reinforcement plate in place for final assembly of the striker. The striker can then be bolted to the reinforcement plate and be positionally adjusted in a conventional manner.

Striker reinforcement for hydroformed automotive door frame

A body side rail construction for an automotive vehicle is formed in a dual cell configuration. A reversed C-shaped channel is welded to the closed section of the conventional roof side rail member to enable the body side rail member to be a smaller section that is less susceptible to buckling as the body side rail member transfers load to the front and rear corner pillars. The C-shaped cross-sectional configuration presents advantages for manufacturing as it can be shaped to provide the attaching brackets and horns for mounting the front header, roof bow, and rear header members to the body side rail without the addition of individual end items to serve this function. From a shipping density standpoint, this design gives maximum structure while maintaining good rack density that enables relatively straight parts to be nested together while still providing the increased section strength required for enhanced roof performance.

Dual cell body side rail for automotive vehicles

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Commerce Township, MI, United States of America

Lou Ratsos