Shape Corporation

Peter Sturrus

Richard D Heinz

James J Rosasco

Douglas L Witte

Kirk W Briggs

Mark Weissenborn

R Clayton McKeon

Thomas F DeVoursney

Leslie A Lewis

Roy Johnson

James A Boos

A method comprises steps of providing bar stock, cutting the stock to form a rod-shaped blank, and stamp-forming a ball section on a first end of the blank in a transfer die. The method further includes stamp-forming an apertured flattened section on a second end of the blank to form a final product in the transfer die, and axially striking opposing ends to accurately form a length of the blank. A related transfer die apparatus includes stations for cutting and then stamp-forming a ball section on a first end of the blank, and stamp-forming an apertured flattened section on a second end of the blank to form a final product.

Stamping apparatus for forming rod with configured ends

A method includes providing an apparatus that includes a scoring device for making transverse score lines on a roll of sheet material, a dimpler device or dimpler roller for making dimples adjacent the score lines at predetermined width locations, and a rollformer adapted to continuously form the sheet material into a tubular shape with channels. A welder is positioned in line with the rollformer and is adapted to weld the tubular shape into a permanent tube. A break off device positioned in line with the rollformer is adapted to break off sections of the tube at the score lines as the permanent tube exits the rollformer. The dimpler device is adapted to form an &ldquo;in&rdquo; dimple and an &ldquo;out&rdquo; dimple at locations coordinated with the score lines and with a width of the sheet material so that the &ldquo;out&rdquo; dimple forms a stop configured to slip into a channel formed in the sheet material by the rollformer but that abuts the &ldquo;in&rdquo; dimple which is formed at an end of the channel.

Method of rollforming with transverse scorer and dimpler

A die apparatus includes a first die configured to telescopingly engage an end section of a tubular bar, including one or more &ldquo;floating&rdquo; mandrels configured to extend into cavities of the tubular bar, and further including a stationary die member spaced from the mandrel(s). The mandrel(s) and the stationary die member include angled cutting edges that are aligned so that the cutting edges are engageable from a single transverse direction. The mandrel(s) is movably supported on the first die to float parallel the single direction toward and away from the stationary die member. A cutting die has a shearing punch configured to move along the single direction to sequentially engage the angled cutting edges to shear off an angled portion of the end section. The die apparatus is optimally designed for use with a rollformed swept tubular bumper bar having a B-shape and that has walls forming first and second tubular sections that define first and second cavities, with the walls further defining a third cavity between the first and second cavities. In such a die apparatus, the first die includes first, second, and third mandrels configured to extend into the first, second, and third cavities, respectively, of the B-bumper. A method related to the above apparatus is also disclosed.

Die apparatus for cutting end of bumper bar

A method includes rollforming and sweeping a tubular beam with a constant longitudinal cross section, and then reforming the tubular beam to form a tubular beam having a non-constant cross section. The non-constant cross sections have specific shapes chosen to provide particular structural properties and surfaces along the reshaped beam, and also to provide a stylized appearance, such that the reformed beam is useful as a vehicle bumper. In particular, the reshaped beam includes integrally formed vehicle mounting structure, angled end sections forming aerodynamic but impact-resistant bumper ends, and a high-energy absorbing but flexible center section.

Vehicle bumper beam with non-uniform cross section

An apparatus includes a scoring device for making transverse score lines on a roll of sheet material, a dimpler device or dimpler roller for making dimples adjacent the score lines at predetermined width locations, and a rollformer adapted to continuously form the sheet material into a tubular shape with channels. A welder is positioned in line with the rollformer and is adapted to weld the tubular shape into a permanent tube. A break off device positioned in line with the rollformer is adapted to break off sections of the tube at the score lines as the permanent tube exits the rollformer. The dimpler device is adapted to form an &ldquo;in&rdquo; dimple and an &ldquo;out&rdquo; dimple at locations coordinated with the score lines and with a width of the sheet material so that the &ldquo;out&rdquo; dimple forms a stop configured to slip into a channel formed in the sheet material by the rollformer but that abuts the &ldquo;in&rdquo; dimple which is formed at an end of the channel.

Rollformer with transverse scorer

An apparatus for forming an end bumper for vehicles constructed from a single sheet of high-tensile strength steel roll-formed to provide two side-by-side tubular sections. Each section has a front wall, an outer side wall, a rear wall, and an inner side wall, the inner side walls being spaced one from the other and connected together by a web roll-formed integrally with the inner side walls. The front walls each have extended ends overlapping and abutting the web. The extreme ends of the front walls also form an abutting juncture which is welded together and also welded to the web. The bumper has a sweep formed by a sweep-forming mechanism having curvilinear an external guide mechanism and internal mandrels conforming to the outer configuration and inner configuration of the bumper so as to provide a passageway therebetween for receiving the bumper. The bumper is passed through the passageway while the roll-forming of the bumper takes place upstream of the mandrels. The inner mandrel is supported by an elongated member extending from the internal mandrel to a support member located where the bending of the terminal lateral ends of the sheet have not yet been completed. A cutting mechanism cuts the bumper at predetermined lengths after the sweeping of the bumper has been completed to continuously form in succession a series of bumpers during the roll-forming of the sheet.

Apparatus for forming an end bumper for vehicles

A multiple panel assembly which is an improvement in the panel assembly of U.S. Pat. No. 3,430,997 in which the four parts of said patent forming the hanger bracket and connector assembly mounted on the opposing edges of two adjacent panel edges is replaced by a unique one-piece hanger bracket/connector strip. Such strip is substantially less costly to manufacture and install on the panel. Within a more narrow aspect of this invention, the wedging members that draw the panel edges toward each other are uniquely configured to accommodate use of the hanger bracket/connector strip with the hanger bracket and connector assembly of U.S. Pat. No. 3,430,997.

Multiple panel assembly and connector assembly therefor

A one-piece dunnage bar for a dunnage rack of the type used to store and transport parts within an automotive factory. The dunnage bar includes integral inner and outer C-shaped portions roll-formed from a single piece of structural metal. The inner and outer portions each include overlying wall segments that cooperate to define the mouth of the C shape. The thickness of each of these wall segments is one-half of the thickness of the remainder of the walls so that the pancaked wall segments have a combined thickness approximately the same as that of the remaining walls.

Dunnage rack bar

An end bumper for vehicles constructed from a single sheet of high-tensile strength steel roll-formed to provide two side-by-side tubular sections. Each section has a front wall, an outer side wall, a rear wall, and an inner side wall, the inner side walls being spaced one from the other and connected together by a web roll-formed integrally with the inner side walls. The front walls each have extended ends overlapping and abutting the web. The extreme ends of the front walls also form an abutting juncture which is welded together and also welded to the web. The bumper has a sweep formed by a sweep-forming mechanism having curvilinear external and internal mandrels conforming to the inner configuration and outer configuration of the bumper so as to provide a passageway therebetween for receiving the bumper. The bumper is passed through the passageway while the roll-forming of the bumper takes place upstream of the mandrels. The inner mandrel is supported by an elongated member extending from the internal mandrel to a support member located where the bending of the terminal lateral ends of the sheet have not yet been completed. A cutting mechanism cuts the bumper at predetermined lengths after the sweeping of the bumper has been completed to continuously form in succession a series of bumpers during the roll-forming of the sheet.

Apparatus for roll-forming end bumper for vehicles

Method of roll-forming an end automotive bumper

A bumper bar for vehicles formed from rolled sheet steel having a closed tubular profile designed to have a high impact resistance, high strength-to-weight ratio, and a low cost of manufacture. The bar is preferably swept along its longitudinal axis to create a curvature consistent with modern automotive designs.

Tubular roll-formed automotive bumper

A bumper bar for vehicles formed from rolled sheet steel having a closed tubular profile designed to have a high impact resistance, high strength-to-weight ratio, and a low cost of manufacture. The bar is preferably swept along its longitudinal axis to create a curvature consistent with modern automotive design.

Growing community of inventors

Grand Haven, MI, United States of America

Peter Sturrus