Metal deforming – By application of fluent medium – or energy field – With actuated tool engaging work
Reexamination Certificate
1999-09-20
2001-04-03
Jones, David (Department: 3725)
Metal deforming
By application of fluent medium, or energy field
With actuated tool engaging work
C029S421100
Reexamination Certificate
active
06209372
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to a hydroformed structural member and, more particularly, relates to a hydroformed structural member having internal hydroformed reinforcements and a method of making the same.
BACKGROUND OF THE INVENTION
It is well known, in the prior art, that the structural or mechanical characteristics of a support member may be improved with the addition of internal reinforcements. This practice is common in the use of stamp-formed members, wherein internal supports are secured, typically by welding, to the stamp-formed member to provide additional localized loading capabilities. However, with the increased popularity and dimensional accuracy of hydroforming, there has been a growing trend to provide additional sectional stiffness as needed for localized loading.
By way of review, hydroforming is essentially the process of deforming a tubular member to a desired complex tubular shape. To this end, the tubular member is placed between a pair of dies having cavities which define the desired resultant shape of the tube. The ends of the tubular member are accessible through the die and a seal is connected to the ends of the tubular member. Pressurized fluid is then injected into the ends of the tubular member, thereby forcing the tubular member to expand and conform to the shape defined by the die cavity.
To provide additional sectional stiffness in hydroformed members, attempts have been made to form hydroformed members having varying wall thickness. This is typically accomplished by welding multiple tubular sections having varying wall thickness together to form a tubular blank. The tubular blank is then hydroformed to produce a member having additional localized stiffness. However, this method is relatively time-consuming and requires additional process steps of assembling and welding the tubular blanks. Lastly, the additional processing steps may further limit the ability to mass produce such items cost effectively.
Accordingly, there exists a need in the relevant art to provide a method of simply and conveniently forming a hydroformed structural member capable of providing additional sectional stiffness while, simultaneously, minimizing the necessary process steps. Furthermore, there exists a need in the relevant art to provide a method of forming a member having internal hydroformed reinforcements. Still further, there exists a need in the relevant art to provide a hydroformed member having internal reinforcements.
SUMMARY OF THE INVENTION
In accordance with the broad teachings of this invention, a hydroformed member having internal reinforcements is provided having an advantageous construction and method of manufacturing the same. The method comprises the steps of providing a die having a tooling cavity and a pair of opposing rams disposed in the tooling cavity. A tubular member is enclosed within the tooling cavity. The pair of opposing rams are then driven against opposing sides of the tubular member to form a pair of opposing indentations therein. While the rams remain in place, hydraulic fluid pressure is then applied within the tubular member causing the walls of the tubular member to closely conform to the shape of the tooling cavity and the pair of opposing rams.
The present invention enables internal reinforcements to be hydroformed within a member to provide improved crash energy management and/or improved load bearing characteristics. The present invention is accomplished in a minimum number of process step, thereby minimizing manufacturing time and complexity and further reducing manufacturing costs.
Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are intended for purposes of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
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pat
Harness & Dickey & Pierce P.L.C.
Jones David
The Budd Company
LandOfFree
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