Figure 1 shows in a schematical perspective view an open extruded member 2 comprising a base portion 21 provided with a rib 22 protruding longitudinally along the member.
Inherent advantages of extruding an open member compared to a closed shape configurated member is a higher extruding speed, less wear of the extruding tool (die), larger choice of applicable alloys and possibility of weight-optimizing of the member by provision of thinner walls when and where appropriate.
Figure 2 illustrates schematically provision of lateral flanges 23,24 by means of any suitable method like e.g. pressing, rolling etc., followed optionally by gradual reduction of the flanges' lateral extension in the direction towards the end of the member by removal/cutting of material as depicted by the hatched fields.
Figure 3 illustrates an interim stage of the reshaping process from open to a closed shape configuration of the member 2 comprising provision of interim side walls 25,26 followed by a further reshaping step along the dotted lines, thereby folding the interim side walls 25,26 into a top portion 27 of a closed shape member by abutting the lateral flanges 23,24 on the top of the longitudinally extending rib 22 as shown in Figure 4a, followed by a joining/welding operation.
Figure 4b shows the formed closed shape member 3 in a preferred embodiment suitable for use as a bumper in vehicles exhibiting a channel-like recession 35 accommodating/- protecting a welding seam (joint) 36 joining the abutted flanges 23,24 and the rib 22, thereby providing two separate chambers 31,32.
Advantageously, thanks to the optional provision of flanges 23,24 exhibiting varying width, the channel recession 35 and thus the whole height H of the beam 3 is decreasing from the OY central line towards the end(s) as illustrated in a perspective view in Fig. 4a. This flexibility with regard to variation of cross-sectional area of the bumper beam is an important advantage resulting from the novel manufacturing method according to the present invention.
Customarily this effect is achieved by deforming (folding) of side walls of readily closed shape extruded members, thus increasing both the weight of the beam, the material consumption and thus the cost of the beams.
Although the present invention has been described and illustrated with respect to the preferred features and manner of manufacturing and preferred embodiments, it is to be understood that various changes and modifications may be made to the specifically described and illustrated arrangements without departing from the scope of the present invention.
Thus Figure 5 illustrates schematically in a perspective view and a cross-sectional view, respectively, a simplified embodiment of the structural member 3 exhibiting a constant height along its longitudinal extrusion. The interim side walls 25,26 from Figure 3 are in this case without provision of any lateral flanges directly folded into a top portion of the thereby provided closed shape member 3 being abutted and joined (welded) along the rib 22 providing two separate chambers 31,32.
Apart from the disclosed joining based on welding of the abutted walls of the member (preferentially friction stir welding), any other conventional joining techniques may be applied depending on the actual demand/performance to the structural member.
Consequently, structural members for different purposes having variation in the cross-sectional configuration, or constant cross-section with option for cutting of members having desired length, can be manufactured according to the present invention.
International Bureau
INTERNATIONAL APPLICATION PUBLISHED UNDER THE PATENT COOPERAΗON TREATY (PCT)
(51) International Patent Classification 1 : (11) International Publication Number: WO 00 35610 B21C 23/14 // B60R 19/02 Al
(43) International Publication Date: 22 June 2000 (22.06.00)
(21) International Application Number: PCT/NO99/00375 (81) Designated States: AE, AL, AM, AT, AU, AZ, BA, BB, BG, BR, BY, CA, CH, CN, CU, CZ, DE, DK, EE, ES, FI, GB,
(22) International Filing Date: 10 December 1999 (10.12.99) GD, GE, GH, GM, HR, HU, ID, IL, IN, IS, JP, KE, KG, KP, KR, KZ, LC, LK, LR, LS, LT, LU, LV, MD, MG, MK, MN, MW, MX, NO, NZ, PL, PT, RO, RU, SD, SE, SG,
(30) Priority Data: SI, SK, SL, TJ, TM, TR, TT, UA, UG, US, UZ, VN, YU,
19985846 14 December 1998 ( 14.12.98) NO ZA, ZW, ARIPO patent (GH, GM, KE, LS, MW, SD, SL, SZ, TZ, UG, ZW), Eurasian patent (AM, AZ, BY, KG, KZ, MD, RU, TJ, TM), European patent (AT, BE, CH, CY, DE,
(71) Applicant (for all designated States except US): NORSK DK, ES, FI, FR, GB, GR, IE, IT, LU, MC, NL, PT, SE),
HYDRO ASA [NO/NO]; N-0240 Oslo (NO). OAPI patent (BF, BJ, CF, CG, CI, CM, GA, GN, GW, ML, MR, NE, SN, TD, TG).
(72) Inventor; and
(75) Inventor/Applicant (for US only): VOLD, Rolf [NO/NO]; Rudsiatten, N-2830 Raufoss (NO). Published
With international search report.
(74) Agent: RICANEK, Ivan; Norsk Hydro ASA, N-0240 Oslo Before the expiration of the time limit for amending the (NO). claims and to be republished in the event of the receipt of amendments.
(54) Title: METHOD OF MANUFACTURING STRUCTURAL MEMBERS (57) Abstract
A novel method of manufacturing structural members having closed cross-sectional configuration comprises steps of providing an open member (2) followed by reshaping/folding of its lateral parts and joining of abutted side walls into a co-extruded supporting longitudinally extending rib (21). The resulting structural member is preferentially a part of a vehicle body structure, e.g. a bumper beam.
FOR THE PURPOSES OF INFORMATION ONLY
Codes used to identify States party to the PCT on the front pages of pamphlets publishing international applications under the PCT.
AL Albania ES Spain LS Lesotho SI Slovenia
AM Armenia FI Finland LT Lithuania SK Slovakia
AT Austria FR France LU Luxembourg SN Senegal
AU Australia GA Gabon LV Latvia SZ Swaziland
AZ Azerbaijan GB United Kingdom MC Monaco TD Chad
BA Bosnia and Herzegovina GE Georgia MD Republic of Moldova TG Togo
BB Barbados GH Ghana MG Madagascar TJ Tajikistan
BE Belgium GN Guinea MK The former Yugoslav TM Turkmenistan
BF Burkina Faso GR Greece Republic of Macedonia TR Turkey
BG Bulgaria HU Hungary ML Mali TT Trinidad and Tobago
BJ Benin IE Ireland MN Mongolia UA Ukraine
BR Brazil IL Israel MR Mauritania UG Uganda
BY Belarus IS Iceland MW Malawi US United States of America
CA Canada IT Italy MX Mexico uz Uzbekistan
CF Central African Republic JP Japan NE Niger VN Viet Nam
CG Congo KE Kenya NL Netherlands YU Yugoslavia
CH Switzerland KG Kyrgyzstan NO Norway ZW Zimbabwe
CI Cate d'lvoire KP Democratic People's NZ New Zealand
CM Cameroon Republic of Korea PL Poland
CN China KR Republic of Korea PT Portugal
CU Cuba KZ Kazakstan RO Romania
CZ Czech Republic C Saint Lucia RU Russian Federation
DE Germany LI Liechtenstein SD Sudan
DK Denmark LK Sri Lanka SE Sweden
EE Estonia LR Liberia SG Singapore
Claims
1. Method of manufacturing longitudinally extending structural members having a closed cross-sectional configuration comprising two or more chambers, said method comprising steps of extruding an open member (2) having a base portion (21) provided with at least one longitudinally protruding rib (22), reshaping of lateral parts of the member into a pair of interim side walls (25,26), folding the interim side walls (25,26) into a top portion (27) of the thereby formed closed shape member (3) by bringing the folded abutted side walls to rest on the longitudinally extending rib (21), and finally joining of the abutted side walls and the supporting rib(s) together by any suitable joining technique known per se.
2. Method according to claim 1, characterized in that the step of reshaping of the lateral parts of the open member (2) further comprises provision of lateral flanges (23,24).
3. Method according to claim 2, characterized in that excess material from the base portion (21) is cut prior to the reshaping step to provide inwardly extending flanges (23,24) exhibiting a varying height along the longitudinal extension of the folded closed shape member.
4. Method according to claim 1 , characterized in that the joining of abutted walls is conducted by friction stir welding.
5. Structural member, particularly for application in a vehicle body structure comprising a hollow shape (3), where the cavity of the hollow shape is longitudinally divided into two or more chambers (31,32) by means of dividing rib(s) (22), characterized in that said rib(s) are integral co-extruded part(s) of open extruded member (2) providing a support for a joint (36) connecting the abutted walls of the folded member (2).
6. Structural member according to claim 5, characterized in that the hollow shape exhibits varying cross-sectional area along its longitudinal extension.
7. Structural member according to claim 5 or 6, characterized in that the joint (36) is a welded seam located in a channel-like recession (35) provided along said member's longitudinal extension by a pair of inwardly extending flanges (23,24).
8. Structural member according to one or more preceding claims, characterized in that the member is a bumper beam for vehicles.