WO2018156882A1

WO2018156882A1 - Crush guiding tubes and methods for same

Info

Publication number: WO2018156882A1
Application number: PCT/US2018/019401
Authority: WO
Inventors: Larry Jay KRIZON
Original assignee: Webco Industries, Inc.
Priority date: 2017-02-24
Filing date: 2018-02-23
Publication date: 2018-08-30

Abstract

A crush guiding tube assembly includes large and small profile tube portions. A crush guide interface is between the large and small profile tube portions. The crush guide interface includes a recess collar and a guide collar. The recess collar extends inwardly from a large interface joint of the large profile tube portion to a guide joint. The guide collar tapers inwardly from a small interface joint of the small profile tube portion to the guide joint, and the guide collar extends toward the large profile tube portion. The guide collar tapers inwardly according to recessing of the guide joint from the large profile tube portion. In a working configuration the guide collar tapers at a first guide angle relative to the small profile tube portion. In a crushing configuration the guide collar tapers at a second guide angle greater than the first guide angle.

Description

CRUSH GUIDING TUBES AND METHODS FOR SAME

PRIORITY APPLICATIONS

This application claims the benefit of priority to U. S. Provisional

Application Serial No. 62/463,329, filed February 24, 2017, the content of which is incorporated herein by reference in its entirety.

COPYRIGHT NOTICE

A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves all copyright rights whatsoever. The following notice applies to the software and data as described below and in the drawings that form a part of this document: Copyright Webco Industries, Inc.; Sand Springs, Oklahoma. All Rights Reserved.

TECHNICAL FIELD

This document pertains generally, but not by way of limitation, to tubes and tubing subject to one or more of crushing or buckling,

BACKGROUND

Vehicles, including automobiles, heavy equipment and the like transmit power to distributed locations away from a motive power source, such as an engine. Tubes, including drives shafts, propeller shafts (i.e., prop shafts) and the like are coupled with the engine. Engine rotation is transmitted through the tubes to one or more outputs including wheels, differentials, power take offs or the like. In at least some examples, the tubes are prop shafts, drive shafts or the like extending through a portion of the vehicle, for instance, adjacent to a passenger or operator

compartment (both herein after referred to as an operator compartment), gas tank or the like.

Vehicles are subject to destructive events including collisions. Collisions, in some examples, crush portions of a vehicle including drive shafts. As a vehicle is crushed, for instance longitudinally or at an angle relative to the longitudinal axis of the vehicle or the drive shaft, the drive shaft is also crushed. Crashing of the drive shaft causes it to buckle, and in some examples the drive shaft buckles into or toward the operator compartment, gas tank or the like. Further, because the drive shaft is (in an example) rotating during the collision it may continue to rotate while at the same time buckling. Either scenario may be dangerous to an operator, passengers or both.

In some examples, drive shafts are constructed with fracturing joints configured to fracture when subject to longitudinal stresses and minimize buckling. In other examples, drive shafts include at least two diameters, a small diameter portion and a (relatively) much larger diameter portion, as well as an interface therebetween. One or more of these features is annealed to decrease its yield strength and facilitate the collapse of the small diameter portion into the large diameter portion. Optionally, the interface is configured to fracture to allow the small diameter portion to collapse into the large diameter portion.

OVERVIEW

The present inventors have recognized, among other things, that a problem to be solved can include minimizing the rupture of a tube (e.g., a drive shaft, propeller shaft, bumper support, or other device application using a tube that may be subject to a one-time energy absorbing collapse) caused by crushing of the tube while at the same time safely controlling the tube as it is crashed. In some examples, tubes, such as drive shafts, are constructed with joints configured to rapture (e.g., fracture, tear or the like) when longitudinally loaded, for instance during a front or rear collision (including head on and angled collisions). The rupture is intended to allow a large diam eter portion of the drive shaft to receive a small diameter portion of the drive shaft. In some examples, the small diameter portion misaligns with the large diameter portion and is only partially received therein or not received at all. Instead, the drive shaft unpredictably buckles and dangerously penetrates the vehicle, for instance an operator compartment or gas tank. The hazard is further compounded if the drive shaft is rotating while it buckles as the shaft may penetrate and sweep through the operator compartment. Further, the industry movement to make stronger tubes (e.g., drive shafts, prop shafts and the like) having higher yield strengths and corresponding resistance to plastic deformation escalates the probability of rapture and hazardous outcomes. In some examples, tubes are made with annealed portions to maintain plastic

deformation with the tradeoff that annealing decreases the strength of the tube and accordingly cuts against the desired higher yield strengths.

The present subject matter helps provide a solution to this problem, for instance with a crash guiding tube assembly including a crush guide interface. The crush guide interface includes a guide collar that tapers inwardly from a small profile tube portion toward a longitudinal tube axis of the crush guiding tube assembly. During a collision (or other energy absorbing collapse) the crush guide interface preferentially deforms (prior to other portions of the tube assembly). In one example, the crush guide interface provides a controlled and guided collapse of a portion of the tube assembly to safely crush the tube and accordingly minimize harm to nearby components, passengers or the like. A recess col lar extending from the large profile tube portion of the tube assembly deforms and rotates inwardly. The recess collar is coupled with the guide collar at a guide joint, and deformation of the recess collar moves the guide joint inwardly and thereby increases the taper of the guide collar. As the tube assembly is crushed the small profile tube portion is guided by the guide collar (now having a greater centrally directed taper) along a specified path of collapse into the large profile tube portion. The small profile tube portion collapses (e.g., prolapses) in a guided manner into the large profile tube portion from its position initially outside of the large profile.

The crush guide interface and the large and small profile tube portions have a relatively consistent yield strength (e.g., with minimal variations in yield strength caused during forming of around 6,000 psi or less, as compared to significant variations in yield strength caused with annealing of around 35,000 psi or more including 35,000-40,000 psi). The crush guide interface is configured to

consistently plastically deform annuiarly (e.g., around the guide interface in a guided, sequential manner), in contrast to rupturing (e.g., partial or full fracturing or tearing, exceeding tensile strength or the like), to ensure the taper of the guide collar predictably and reliably guides the moving small profile tube portion into the large profile during the collision or other crushing event.

In other examples, the relatively small radius of the large interface joint and the relatively steep recess angle promote crushing at the crush guide interface before other locations of the tube assembly and cause the recess collar to rotate inwardly while ensuring the guide collar (tapered) guides the small profile tube portion inwardly and captures the small profile as discussed herein. Any rupture at the crush guide interface or at the large or small profile tube portions adjacent the interface occurs (if at all) after the small profile tube portion is received and captured (e.g., held, retained or the like) within the large profile tube portion.

Accordingly, because rupturing is minimized (at least during initial crushing), the predictable guidance along a specified path of collapse and capture of the small profile tube portion in the large profile tube portion is enhanced.

The present inventors have recognized that another problem to be solved can include maximizing the structural integrity of a tube, such as a drive shaft, while also enhancing the predictability of safe caishing of the tube. In some examples, tubes, such as dri ve shafts or other tubes used in other device applications that may be subject to a one-time energy absorbing collapse, are constructed with small and large diameter portions to facilitate the reception of the small diameter portion within the large diameter portion during a collision (e.g., as the drive shaft is crushed). As discussed above, fracture between the large and small diameter portions may be hazardous. Further, the variation of diameter from the large diameter to the small diameter decreases the torsional strength in the small diameter portion and correspondingly limits the application of torque to the drive shaft. In other examples, portions of the drive shaft are annealed to decrease the incidence of fracture in a collision. In these examples, annealing a portion of the drive shaft decreases the structural integrity (e.g., yield strength or the like) and similarly limits the torque applied to the drive shaft without causing failure (including yield, rupture or the like).

The present subject matter helps provide a solution to these problems, for instance with a crush guiding tube assembly having a crush guide interface that minimizes the difference in profile (e.g., diameter) between large and small profile portions of the tube assembly while at the same time ensuring reliable and predictable reception of the small profile portion within the large profile portion during crushing. The crush guiding tube assembly is, for instance, not annealed at either of the crush guide interface or the adjacent large or small profile tube portions. Instead, the tube assembly has a consistent yield strength (e.g., with a variation of up to 6000 psi compared to annealed variations of 35,000 psi or more) configured to provide high strength while at the same time ensuring plastic deformation of the crush guide interface and optionally the surrounding tube portions so the small profile portion is reliably and safely received in the large profile portion during crushing (e.g., in a vehicle collision).

Further, because of the crush guide interface the small profile portion includes a profile (e.g., diameter) approaching that of the large profile portion. The taper of the guide collar in cooperation with deformation of the recess collar ensures even a large (relatively) small profile portion compared to the large profile portion is guided into and captured by the large profile during crushing. In some examples, the small profile portion of the tube assembly includes a profile (e.g., a diameter) 91 percent of the large profile portion of the tube assembly. Because the small profile portion is relatively large the crush guiding tube assembly has greater structural integrity and corresponding increased mechanical characteristics including, but not limited to, torsional strength (e.g., yield strength in the context of torque), decreased transmission losses (e.g., efficiency, based in part on resistance to deformation during torqueing) and the like. These enhancements are further compounded because the crush guiding tube assembly is not annealed, and instead each of the crush guide interface and the large and small profile tube portions maintains elevated strength (e.g., yield strength) relative to annealed counterpart tubes.

This overview is intended to provide an overview of subject matter of the present patent application. It is not intended to provide an exclusive or exhaustive explanation of the disclosure. The detailed description is included to provide further information about the present patent application.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, which are not necessarily drawn to scale, like numerals may describe similar components in different views. Like numerals having different letter suffixes may represent different instances of similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.

Figure 1 is a bottom view of a vehicle including one example of a crush

guiding tube assembly.

Figure 2 is a cross sectional view of another example of a crush guiding tube assembly.

Figure 3 is a detailed cross-sectional view of one example of a crush guide interface.

Figure is a cross sectional view of the crush guiding tube assembly of Figure 2 in a crushing configuration.

is a cross sectional view of the crush guiding tube assembly of Figure 2 in a captured configuration.

is a cross sectional view of the crush guiding tube assembly of Figure 2 in a second captured configuration.

is a cross sectional view of the crush guiding tube assembly of Figure 2 in the captured configuration with the tube assembly ruptured, is a cross sectional view of the crush guiding tube assembly of Figure 2 in the captured configuration with the tube assembly further telescoped.

is a perspective view of a tube assembly blank,

is a perspective view of a multiple profile intermediate tube assembly.

is a perspective view of one example of a crush guiding tube assembly.

is a perspective of another example of a tube assembly blank, is a perspective of another example of a crush guiding tube assembly, is a block diagram showing one example of a method for guiding crashing of a crush guiding tube assembly.

DETAILED DESCRIPTION

Figure 1 shows a schematic view of an example vehicle 100, As shown, the vehicle 100 includes an output assembly 102 including, for instance, one or more of a motor, transmission, transfer case or the like in communication with a mechanical output 108. The mechanical output 108 in this example includes, but is not limited to, one or more of differentials, wheels or the like. In another example, the mechanical output 108 is another form of mechanical output including, but not limited to, a pump, rotor, rotating armature or the like. As further shown in Figure 1, the output assembly 102 is coupled with the mechanical output 108 with a shaft, for instance, a drive shaft, propeller (prop) shaft or the like. In the example shown, the shaft includes a caish guiding tube assembly 104 extending from the output assembly 102 to the mechanical output 108

(optionally, with one or more intervening components therein, for instance, a differential or the like). The crush guiding tube assembly 104 is configured to transmit rotation from the output assembly 102 to the mechanical output 108. As described herein, the crush guiding tube assembly 104 includes a crash guide interface 106 (shown with broken lines in Figure 1 ). The crash guide interface 106 provided at one or more locations along the crash guiding tube assembly 104 controls and guides deformation of the crush guiding tube assembly 104, for instance, during a collision or other violent contact with the vehicle 100 that causes crushing of the assembly 104. As further described herein, the crush guide interface 106 localizes the deformation of the assembly 104 to the crush guide interface 106. For instance, deformation of the assembly 104 is preferentially initiated at the crush guide interface 106. The crash guide interface 106 guides the translation of a portion of the assembly 104, for instance, a small profile tube portion into a large profile tube portion.

Additionally, during a crushing event the crush guide interface 106 plastically deforms at the interface 106 and maintains a connection between the small and large profile tube portions of the crush guiding tube assembly 104 at least until the small profile tube portion is received and captured within the large profile tube portion. Accordingly, instead of rupturing, for instance, at an interface or other feature of the assembly 104, the small profile portion is received within the large profile portion and captured therein. In the example including the vehicle 100, during operation rotation is transmitted along the crush guiding tube assembly 104 to the mechanical output 108. in the event of a collision, the deformation of the crush guiding tube assembly 104 including crushing of the assembly 104 occurs, in one example, while the crush guiding tube assembly 104 is rotating. The crush guide interface 106 ensures reception and capture of the small profile tube portion of the assembly 104 within the large profile tube portion of the assembly 104 and minimizes hazardous outcomes including buckling of other shafts and continued rotation of buckled shafts (e.g., through passenger compartments, cabins, through other vehicle or machine systems or the like). The example crush guiding tube assemblies described herein thereby maintain the various tube portions in a linear or near linear configuration during a crushing event while at the same time minimizing one or more buckling, rotating of a buckled shaft or the like.

Figure 2 shows a cross-sectional view of one example of the crush guiding tube assembly 104. As shown, the cmsh guiding tube assembly 104 includes a large profile tube portion 200 having a large profile (inner) diameter 216 and a small profile tube portion 202 having a small profile (outer) diameter 218. In one example, the small profile diameter 218 is smaller than the large profile diameter 216. For instance, in one example, the small profile diameter 218 is 91 percent or less of the large profile inner diameter 216. As described herein, the crush guide interface 106 preferentially guides even relatively large small profile tube portions 202 into similarly sized large profile tube portions 200 (e.g., having a diameter relationship of 91 percent or less). In contrast to assemblies with small diameter tubes that are 70 percent or less of the large diameter large tubes and having variation in strength of 35,000 psi or more, the similarly sized tubes 200, 202 of the crush guiding tube assembly 104 include minimal variation in strength (e.g., torsional strength as a function of yield strength) of around 6,000 psi or less. The crush guiding tube assembly 104 minimizes the variation in torsional strength (and yield strength) while at the same time minimizing buckling and consistently and reliably capturing the small profile tube portion 202.

Referring again to Figure 2, the crush guiding tube assembly 104 includes the crush guide interface 106 interposed between each of the small and large profile tube portions 202, 200. The cmsh guide interface 106, as previously described herein, is configured to guide deformation of the crush guiding tube assembly 104, for instance, during a collision or other event that transmits force along the assembly 104, including but not limited to compressive forces directed along a longitudinal tube axis 204 or at an angle relative to the longitudinal tube axis 204 (in a manner that applies compressive force along the tube assembly 104).

The crush guide interface 106 includes a guide collar 208 extending from a small interface joint 214 of the small profile tube portion 202. The guide collar 208 is tapered, for instance, toward the longitudinal tube axis 204 and the large profile tube portion 200. As shown in Figure 2, the guide collar 208 tapers from the profile of the small profile tube portion 202 toward the interior of the large profile tube portion 200. As further shown in Figure 2, a guide joint 212 is provided at an opposed end of the guide collar 208 relative to the small interface joint 214. The guide joint 212 provides an interface between the guide collar 208 and a recess collar 206. The recess collar 206 extends from a large interface joint 210 of the large profile tube portion 200 to the guide joint 2 2.

As shown in Figure 2, in this example, the recess collar 206 is provided at a steeper angle (a recess angle) relative to the guide collar 208 (having a guide angle). The recess collar 206 and the guide collar 208 provide an to the crush guide interface 106 and positions the guide joint 212 at a recessed or undercut position relative to each of the small profile tube portion 202 and the large profile tube portion 200 (e.g., the tube walls, diameters or the like). In another example, the guide joint 212 is provided at a recessed location or position relative to one or more diameters of the large and small profile tube portions 200, 202 including, for instance, the large profile diameter 216 and the small profile diameter 218 shown in Figure 2.

Figure 3 shows a detailed cross-sectional view of a portion of the crush guide interface 106 shown in Figure 2. In this example, the crush guide interface 106 includes the recess collar 206 extending from the large interface joint 210 proximate the large profile tube portion 200 to the guide joint 212. The guide collar 208 extends from the small interface joint 214 to the guide joint 212, and meets the recess collar 206. Accordingly, as shown, the crush guide interface 106 includes an undercut configuration (e.g., a working configuration) with the guide joint 212 provided at a joint position 308 shown, for instance, in Figure 3. In the working configuration shown in Figure 3, the joint position 308 of the guide joint 212 is positioned closer to the longitudinal tube axis 204 in comparison to other portions of the crush guiding tube assembly 104,

As further shown in Figure 3, the recess collar 206 is at a recess angle 304 relative to the large profile tube portion 200. Similarly, the guide collar 208 is provided at a guide angle 306 relative to the small profile tube portion 202. In the example shown, the guide angle 306 is smaller than the recess angle 304, and accordingly the guide collar 208 includes a more gradual (e.g., less steep) taper than the recess collar 206. The gradual taper of the guide collar 208 ensures the small profile tube portion 202 has a profile that is similar to the profile of the large profile tube portion 200. The steep taper of the recess collar 206 ensures the collar 206 assumes the transition from the large profile tube portion 200 to the guide joint 212 and allows the gradual transition from the small profile tube portion 202 to the guide joint 212 is comparably less. Accordingly, the undercut joint position 308 is positioned inwardly relative to both the large and small profile tube portions 200, 202, promotes crushing at the crush guide interface while maintaining a relatively large profile of the small profile tube portion 202. The similar profi les of the large and small profile tube portions 200, 202 increase the strength (e.g., torsional strength) of the crush guiding tube assembly 104 and minimizes failure in the small profile tube portion 202 in comparison to other assemblies including small tube portions having profiles smaller than described herein.

The configuration of the crush guide interface 106 shown in Figure 3 corresponds to a working configuration of the crush guiding tube assembly 104 prior to plastic deformation or yielding of the crush guiding tube assembly 104. The crush guiding tube assembly 104, in this configuration, is configured to transmit power, for instance, rotation or the like along the crush guiding tube assembly 104 to one or more mechanical outputs such as the mechanical output 108 shown in Figure 1 whi le minimizing failure of the assembly, for instance at or proximate to the small profile tube portion 202. Further, the undercut of the crush guide interface 106 (e.g., at the guide joint 212) facilitates the deformation and capture of the small profile tube portion 202 within the large profile tube portion 200 even while the small profile tube portion 202 has a profile such as a diameter or the like proximate to the corresponding diameter of the large profile tube portion 200.

Accordingly, power, torque, rotation or the like is reliably transmitted along the crush guiding tube assembly 104 with minimized power loss, yielding

deformation or the like of the crush guiding tube assembly 104. Similarly, the crush guiding tube assembly 104 having the configuration shown, for instance, with the undercut crush guide interface 106 consistently and reliably resists deformation, for instance, yielding or the like, due to rotational stresses applied along the drive shaft and accordingly permits the transmission of increased power, torque or the like along the crush guiding tube assembly 104. In contrast, other tube assemblies, for instance, having a smaller profile tube portion relative to the large profile tube portion (e.g., with diameters of 80, 70, 60 percent or less than the large profile) are more prone to failure at or proximate to the smaller profile portion .

Figure 4 shows the crush guide interface 106 in an intermediate

configuration, for instance, an initial crushed configuration. As shown, the crush guiding tube assembly 104 includes the small and large profile tube portions 202, 200 with the crush guide interface 106 therebetween. In the view shown in Figure 4, the crush guide interface 06 has begun deformation, for instance, plastic deformation (yield) to accordingly receive and capture the small profile tube portion 202 within the large profi le tube portion 200.

The recess collar 206 is rotated relative to the configuration previously shown in Figure 3 as the large interface joint 210 yields. For instance, the recess collar 206 in the view shown in Figure 4 has rotated inwardly, the recess angle 304 is increased, and the collar 206 has everted relative to the previous configuration (projecting outwardly from the large interface joint 210 in Figure 3). The recess collar 206 now extends within the large profile tube portion 200. Additionally, the guide joint 212, for instance, provided at an opposed end of the recess collar 206 is moved inwardly, for instance, closer to the longitudinal tube axis 204, by the rotated recess collar 206. The guide joint 212 is at a second joint position 308 shown in Figure 4 (and recess inwardly relative to the position 308 shown in Figure 3). The joint position 308, in one example, corresponds to a crushing diameter 402 of the guide joint 212 of the crush guiding tube assembly 104 shown in Figure 4. For illustration purposes, the larger working diameter 400 of the guide joint 212 in the initial working configuration is juxtaposed to the crushing diameter 402.

As shown, the crushing diameter 402 is smaller relative to the working diameter 400 and illustrates the inward positioning of the guide joint 212, for instance, according to rotation of the recess collar 206 into the intermediate crushing configuration shown in Figure 4. in one example, the rotation of the recess collar 206 is instituted by compressive forces applied along the tube assembly 104 (including at angles relative to the axis 204). The crushing forces drive the small profile tube portion 202 toward the large profile tube portion 200. The crush guide interface 106 preferentially rotates, folds, crushes or the like at one or more of the large interface j oint 210, the guide j oint 212 or the small interface j oint 214. For instance, as shown in Figure 4 the crushing interface 106 folds and absorbs the force delivered along the tube portions.

Continued crushing of the crush guiding tube assembly 104 translates the small profile tube portion 202 toward the large profile tube portion 200 and the guidance provided by the crush guide interface 106 ensures the small profile tube portion 202 is received within the large profile tube portion 200. Referring again to Figure 4, with rotation of the recess collar 206, for instance, into the intermediate crushing configuration shown in Figure 4, the guide joint 212 at the inward joint position 308 (relative to Figure 3) further tapers the guide collar 208. For instance, the guide angle 306 shown for the guide collar 208 relative to the small profile tube portion 202 is greater than the original angle 306 shown in Figure 3. Because the guide joint 212 is moved inwardly, for instance, toward the longitudinal tube axis 204 relative to the position shown in Figure 3, the guide collar 208 further tapers inwardly as well. Accordingly, the taper of the guide collar 208 is increased in the intermediate crushing configuration shown in Figure 4 relative to the working configuration shown in Figure 3.

The contraction of the guide collar 208 into the configuration shown in Figure 4 including additional tapering toward the longitudinal tube axis 204 enhances the guidance of the small profile tube portion 202 into the large profile tube portion 200 by more centrally directing the guide collar 208 relative to the working configuration in Figure 3. Accordingly, one or more of misalignment, buckling or the like of the small profile tube portion 202 relative to the large profile tube portion 200 is minimized with operation of the deforming crush guide interface 106.

Because the crush guiding tube assembly 104 maintains the working configuration shown in Figure 3, including the crush guide interface 106 having the moderate taper of the guide collar 208 and outward location of the guide joint at position 308 (relative to Figure 4) the assembly 104 is able to receive and transmit rotation and torque without yielding as in other tube assemblies. Instead, the crush guide interface 106 provides a minimal transition between the large and small profile tube portions 200, 202, that facilitates the use of a small profile tube portion 202 having a profile similar to the large profile tube portion 200 (e.g., 91 percent or less). Furthermore, the crush guide interface 106, even with the small profile tube portion 202 described herein, is configured to reliably deform (e.g., fold, crumple, crush or the like) in a manner that consistently directs the small profile tube portion 202 into the large profile tube portion 200.

In another example, and as shown in Figure 4, the large profile tube portion 200 includes a large profile trumpet 404. For instance, as shown, the large profile trumpet 404 is, in one example, a portion of the large profile tube portion 200 proximate to the large interface joint 210. The deformation at the crush guide interface 106, for instance, at each of the large interface joint 210, the guide joint 212 and the small interface joint 214 biases the portion of the large profile tube portion 200 proximate to the crush guide interface 106 into an outwardly projecting configuration relative to the working configuration shown, for instance, in Figure 3. Instead, the large profile trumpet 404 extends outwardly or expands relative to the remainder of the large profile tube portion 200 and accordingly provides an enlarged opening for reception of the small profile tube portion 202 therein. The increased taper of the guide collar 208 (in the crushing configuration) in combination with the large profile trumpet 404 further enhances the guidance of the small profile tube portion 202 into the large profile tube portion 200 for eventual capture (as shown in Figures 5A, 5B, 6A and 6B).

Figure 5A shows the crush guide interface 106 of the crush guiding tube assembly 104 in another crushing configuration with the small profile tube portion 202 captured within the large profile tube portion 200. In the view shown in Figure 5 A, at least a portion of the small profile tube portion 202 is received and captured within the large profile tube portion 200, for instance, according to deformation at the crush guide interface 106 including (e.g., yield or plastic deformation without rupture) as previously shown and described in Figure 4.

The crush guide interface 106 continues to plastically deform (relative to the configuration in Figure 4) with crushing of the crush guiding tube assembly 104. For instance, as the small profile tube portion 202 continues to move toward the large profile tube portion 200, the crush guiding interface 106 including one or more of the recess collar 206, the guide collar 208 and one or more of the large interface joint 210, guide joint 212 or small interface joint 214 deforms (e.g., yields, folds, crumples, crashes or the like). For instance, as shown in Figure 5A, the recessed collar 206 continues to evert into the large profile tube portion 200 relative to the configurations shown in Figures 3 and 4, and as shown is folded along an interior of the large profile tube portion 200. Additionally, the large interface joint 210 and the guide joint 212 at either end of the recess collar 206 continue to deform (e.g., yield) and thereby fold the crush guide interface 106 into the configuration shown in Figure 5 A with both of the recess collar 206 and the guide collar 208 folded along each other.

With the continued eversion of the recess collar 206 the small profile tube portion 202 is drawn into, received and captured within the large profile tube portion 200 as shown in Figure 5 A. For instance, the small profile tube portion 202 is telescopically received within the large profile tube portion 200 while maintaining coupling between each of the portions 200, 202. The continued plastic deformation at the crush guide interface guides the small profile tube portion 202 into the large profile tube portion 200 at least until the small profile tube portion 202 is captured therein. Rupture of the caish guiding tube assembly is minimized (e.g., eliminated or minimized) through the controlled plastic deformation at the crush guide interface 106.

In one example, the crush guide interface 106 in the crushing configuration is configured to provide a composite bend radius, for instance, a tear drop profile (further described and shown in Figure 5B and shown in an initial configuration in Figure 5A) including component bend radii along each of the recess collar 206 and the guide collar 208. The folding of the crush guide interface 106, for instance, between the guide collar 208 and the recess collar 206 generates the tear drop profile. The tear drop profile and the gradual turn at the interface 106 between the small profile tube portion 202 and the large profile tube portion 200 facilitates the continued plastic deformation at the crush guide interface 06 without rupturing.

Figure 5B shows another crushing configuration of the crush guiding tube assembly 104 including additional deformation relative to the deformation shown in Figure 5 A. For instance, the crush guide interface 106 has continued to evert, for instance, with the recess collar 206 fully folded beneath the large profile tube portion 200. As shown in Figure 5B, the crush guide interface 106 is identifiable with the deformed crush guiding tube assembly 104. For instance, the guide collar 208 extends from the small interface joint 214 toward the guide joint 212 and the recess collar 206 extends from the guide joint 212 to the large interface joint 210.

The crush guide interface 106 has guided deformation of the interface 06 into the tear drop profile 506 shown in Figure 5B. The tear drop profile 506 is shown as a composite bend radius 500 provided by each of the joints 212, 214 as well as the intervening guide collar 208. For instance, as shown, a component bent radius 502 proximate to the guide joint 212 and a component bent radius 504 proximate to the small interface joint 214 additively form the gradual composite bent radius 504 of the tear drop profile 506. The large radius of the composite bent radius 500 including each of the component bent radii 502, 504 is relatively large to otherwise sharp corners, bends or the like that include tight radii. During deformation a tight radius in other tube assemblies is prone to rupture and accordingly one or more buckling of the tube assembly, misalignment between crushing tubes, failure to receive or capture a tube portion in another tube portion.

In contrast to tight radii, with the relatively large composite bent radius 500 of the tear drop profile 506, plastic deformation of the crush guide interface 106 is promoted until at least the small profile tube portion 202 is captured while rupture (e.g., failure, splitting, cracking or the like) at the crash guide interface 106 or in portions of the large or small profile tube portions 200, 202 is minimized.

Accordingly, the crash guiding tube assemblies 104 having the crush guide interface 106 described herein is configured to facilitate the consistent and reliable reception and capture of portions of the tube assembly within other portions of the assembly (e.g., capture of the small profile within the large profile), and does so while minimizing rupture at least until capture even with tube assemblies having high torsional strengths (as a function of yield strengths). The crash guide interface 106 is not annealed, and accordingly the tube assembly provides consistent mechanical characteristics in each of the large and small tube profile portions 200, 202 as well as the crush guide interface 106. For instance, the yield strength in each of the portions 200, 202 and the crush guide interface 106 varies by 8,000 psi or less; 6,000 psi or less; 4,000 psi or less or the like (in contrast to variations of 35,000 psi or more at annealed crush absorbing features). The consistent strength of the crush guiding tube assembly 104 is further enhanced because in the working configuration (Figures 2 and 3) the crush guide interface 106 having the recess collar 206, guide collar 208 and the guide joint 212 provides an overall minimal change in diameter between the small and large profile tube portions 202, 200 that facilitates the use of relatively large small profile tube portions 202 compared to the large profile tube portions 200 that allows for the transmission of high torque through the assembly 104. Even with consistent and unannealed mechanical characteristics and a relatively large profile for the small profile tube portion 202 the crush guide interface 106 plastically deforms (yields) and reliably guides, receives and captures the small profile tube portion 202 in the large profile tube portion 200 while minimizing buckling and misalignment of tubes.

Optionally and as shown in Figures 6 A and 6B, after reception and capture of the small profile tube portion 202 within the large profile tube portion 200 (as shown in Figures 5A or 5B), the interface 106 between the small and large profile tube portions 202, 200 ruptures. After capture of the small profile tube portion 202, the crush guide interface 106, in some examples, fails and accordingly ruptures to separate the small profile tube portion 202 from the large profile tube portion 200. However, becau se of the preceding reception and capture of the small profile tube portion 202 (by way of plastic deformation of the crush guide interface 106) the small profile tube portion 202 does not unseat, escape or back out from the large profile tube portion 200 and is, therefore, safely held and maintained therein.

Figures 6 A and 6B show the crush guiding tube assembly 104 in additional crushing configurations. Figure 6 A, for instance, shows the crush guide interface 106 in an everted configuration, for instance, similar the eversion shown in Figures 5A and 5B, For instance, the recess collar 206 is rotated in an opposite direction relative to the working configuration shown in Figures 2 and 3. Additionally, in one example the guide collar 208 as well as one or more of the small interface joint 204 and the guide joint 212, in an example, deform into a composite bend radius or tear drop profile previously shown in Figure 5B,

In the example shown in Figure 6A, the crush guide interface 106 includes a rupture, for instance, a split, fracture or the like between the large profile tube portion 200 and the small profile tube portion 202. As shown in Figure 6A, the rupture is localized along the recess collar 206, for instance, between the guide joint 212 and the large interface joint 210, As will be described herein, the recess collar 206, in this example, acts as a capture flange or ruptured captured flange configured to provide mechanical engagement between the large profile tube portion 200 and the ruptured portion of the small profile tube portion 202 captured within the tube portion 200.

As shown in Figure 6 A, the crushing of the crush guide interface 106 guides the small profile tube portion 202 into the large profile tube portion 200 for reception and capture therein. Continued movement of the small profile tube portion 202 is received within the large profile tube portion 200. Accordingly, as shown in Figures 5A, 5B, the small profile tube portion 202, after crushing at the crash guide interface 106, captures the small profile tube portion 202 therein.

Additional deformation at the crash guide interface 106 and in one or more of the large profile tube portion 200 or small profile tube portion 202 further translates the small profile tube portion 202 into the large profile tube portion 200. In some examples, continued deformation ruptures the crush guide interface 106 and correspondingly separates the small profile tube portion 202 from its integral connection with the large profile tube portion 200.

Because the crash guide interface 106 is everted at rapture, for instance, with the recess collar 206 directed in an opposed direction to the working configuration (see Figures 2 and 3), the recess collar 206 provides a flange, boss, anchor, stop or the like (e.g., collectively referred to as a capture flange) configured to engage with the corresponding portion of the small profile tube portion 202, for instance, a portion of the crush guide interface 106, such as the remainder of the recess collar 206 shown, for instance, in Figure 6A. The capture flange (e.g., a portion of the everted recess collar 206) intercepts movement of the small profile tube portion 202 in an opposed direction that may otherwise unseat the small profile tube portion 202 from the large profile tube portion 200. Further, portions of the recess collar 206 associated with the large profile tube portion 200 engage with the portions of the recess collar 206 associated with the second profile tube portion 202 (e.g., the capture flange) and substantially prevent the decoupling of the small profile tube portion 202 from the capture configuration shown in Figure 6A. Accordingly, the crush guide interface 106, in one example, provides one or more features such as the recess collar 206 as a capture flange that retains the small profile tube portion 202 within the large profile tube portion 200 and thereby maintains the capture configuration. Rupture and uncontrolled corresponding disconnection between one or more of the small profile and the large profile 202, 200 is thereby minimized (e.g., minimized or eliminated).

In one example, the crush guide interface 106 is configured to rupture (if at all) in a preferential manner at the recess collar 206, As previously described and shown, for instance, in Figure 3, the large profile tube portion 200 includes the first wall thickness 300 (also shown in Figure 6A) and the small profile tube portion 202 includes a second wail thickness 302 greater relative to the first wail thickness 300. Because the second wall thickness 302 is greater than the first wall thickness 300, rupture of the crush guiding tube assembly 104, in one example, is preferentially provided in those portions of the assembly 104 that are relatively more thin.

Additionally, because the recess collar 206 yields and is plastically deformed during crushing of the crush guide interface 106 (e.g., rotated, everted or the like), the recess collar 206 is accordingly weakened in addition to having a thinner wall thickness relative to the small profile tube portion 202. Accordingly, rupture of the crush guiding tube assembly 104 is preferentially initiated, if at all, along the recess collar 206. Because mpture is preferentially located along the recess collar 206 and the recess collar 206 maintains capture of the small profi le tube portion 202 as described herein the crush guide interface 106 reliably maintains capture of the small profile tube portion 202 even with a rupture of the tube assembly 104.

Figures 7 A, 7B and 7C show one example of the formation of a crush guide interface 716 similar, in at least some regards, to the crush guide interface 106 shown in Figures 2 and 3. As shown in Figure 7 A, in one example, the initial component of the crush guiding tube assembly 704 includes an isodiametric base tube 700. The isodiametric base tube 700 is formed into an intermediate

configuration, for instance, a multiple profile intermediate tube assembly 702 including the intermediate interface 710 shown in Figure 7B. In one example, end forming is used to form the intermediate interface 710. End forming includes, but is not limited to, one or more of rotary swaging, radial forging, spin forming, hydro forming or the like to form the intermediate interface 710.

As further shown in Figure 7B, the intermediate interface 710 provides a graduated interface between a large profile tube portion 706 and a small profile tube portion 708 having a profile smaller than the large profile tube portion 706. As further shown in Figure 7B, the intermediate interface 710 provides a widening intermediate taper that transitions from the small profile tube portion 708 to the large profile tube portion 706. In contrast to the crush guide interface 716 shown, for instance, in Figure 7C, the components of the intermediate interface 710 that correspond to the interface 716 in Figure 7C are, in this example, provided in a widening configuration to accordingly facilitate the transition between the small and large profile tube portions 708, 706. As shown in Figure 7B, the intermediate interface 710 of the multiple profile intermediate tube assembly 702 extends from an interface root 712 proximate to the large profile tube portion 706 to an interface end 714 proximate to the small profile tube portion 708.

Referring now to Figure 7C, the multiple profile intermediate tube assembly 702 shown in Figure 713 is transitioned to the crush guiding tube assembly 704. As shown, the crush guiding tube assembly 704 includes a crush guide interface 716 including each of the recess collar 718 and a guide collar 724. As previously described, the recess collar 718 tapers from the large interface joint 720

(corresponding to the interface root 712 shown in Figure 7B, in one example) toward the guide joint 722. The guide collar 724 correspondingly tapers from the small interface joint 726 to the guide joint 722. In contrast to the intermediate interface 710 shown in Figure 7B, the crush guide interface 716 has an inverted configuration and accordingly tapers toward the guide joint 722 in contrast to the widening taper in Figure 7B from the interface end 714 toward the interface root 712. Stated another way, the crush guide interface 716 includes the undercut configuration previously shown and described in Figures 2 and 3, and the guide joint 722 is recessed relative to each of the small profile tube portion 708 and the large profile tube portion 706.

Accordingly, the guide collar 724 in combination with the recess collar 718 is configured to deform (including, but not limited to, crush, fold, crumple or the like) with crushing forces applied along the crush guiding tube assembly 704 (e.g., forces greater than or equal to the assembly yield strength). The guide collar 724 is configured to guide translation of the small profile tube portion 708 into the large profile tube portion 706. In one example, the deforming of the crush guide interface 716, for instance, the recess collar 718 moves the guide joint 722 inwardly and accordingly increases the taper of the guide collar 724. As described herein, the increased taper of the guide collar 724 provides enhanced guidance to the small profile tube portion 708 and accordingly ensures reception of the small profile tube portion 708 within the large profile tube portion 706. In another example, the guide collar 724 having the increased taper provided by the rotating recess collar 718 provides enhanced guidance of the small profile tube portion 708 into the large profile tube portion 706 and accordingly minimizes one or more of buckling, misalignment or the like.

Referring to Figures 7C and 7B, the recess collar 72718 is, in one example, formed according to deformation provided along the intermediate interface 710. For instance, in one example, a die, tool or the like is engaged against the intermediate interface 710 and deforms the interface to form the recess collar 718 into the profile shown in Figure 7C. For instance, the die is engaged along that portion of the intermediate interface 710 corresponding to the recess collar 7 8 in Figure 7C. Deformation of the material of the tube assembly forms the recess collar 718 at an acute recess angle, for instance, the recess angle 304 shown in Figure 3.

In an example including formation of the recess collar 718 with a die, in one example, the guide collar 724 is formed through bowing or deflecting of that portion of the intermediate interface 710 corresponding to the guide collar 724 during deformation of the recess collar 718, For instance, as the die is engaged along the intermediate interface 710 to form the recess collar 718, the remainder of the intermediate interface 710 corresponding to the guide collar 724 bows or deflects around the die and assumes an inwardly tapering configuration (an example is shown in Figure 3). As that portion of the intermediate interface 710 bows around the die, the remainder of the intermediate interface, for instance, extending from the guide joint 722 to the small interface joint 726 assumes a substantially linear configuration extending at an angle, such as the guide angle 306 shown in Figure 3. In one example, the guide angle 306 is an acute angle and has an angle measure smaller than the recess angle 304 shown in Figure 3. Accordingly, the recess collar 206 has a steeper taper relative to the guide collar 208 as shown in Figure 3 and similarly the recess collar 718 shown in Figure 7C has a steeper taper relative to the guide collar 724. With each of the guide collar 724 and the recess collar 718 formed, the crush guide interface 716 is completed.

The forming of crush guide interface 716 includes deformation of the intermediate interface 710 to form each of the recess collar 718, the guide collar 724 and position or rotate these features relative to one or more other locations of the interface including the large and small interface joints 720, 722 and the guide joint 722. The crush guide interface 716 is deformed, but not annealed, in one example to maintain the mechanical characteristics of the base material of the tube assembly 704. Other example tube assemblies selectively anneal the material at an interface to promote yield at the interface. However, annealing decreases the robust mechanical characteristics of the tube assemblies and accordingly limits the torque transmitted through the assemblies before yielding. In contrast, the forming methods described herein do not anneal the crush guide interface 716 (or 106) described herein. The crush guide interfaces 716, 106 instead guide yielding according to shaping of the interfaces (e.g., at the recess collars and guide collars) to ensure the small profile tube portion is guided into the large profile tube portion and captured herein. Accordingly, the crush guiding tube assembly 704 (and 104 herein) transmit higher torque while minimizing buckling of the assembly without annealing.

Figures 8 A and 8B show another example of the formation of a crush guide interface, such as the crush guide interface 808 shown in Figure 8B. In this example, an isodiametric base tube 800 is formed into the crush guiding tube assembly 802 including the crush guide interface 808 in a single formation step. For instance, the intermediate interface 710 shown in Figure 7B in the previous example is not included with the forming shown in Figures 8A and 8B.

Referring now to Figure 8B, the crush guiding tube assembly 802 is shown with the crush guide interface 808, The crush guide interface 808 includes a recess collar 810 tapering inwardly relative to both the small and large profile tube portions 806, 804 and a guide collar 816 also tapering inwardly as shown in Figure 8B (both inwardly tapering toward the longitudinal tube axis of the assembly 802). As previously described herein, the crush guide interface includes a large interface joint 812 and a small interface joint 818. Each of the recess collar 810 and the guide collar 816 taper from the respective large interface joint 812 and small interface joint 818 toward a guide joint 814.

In one example, the crush guide interface 808 shown in Figure 8B is formed from the isodiametric base tube 800 through one or more methods including, but not limited to, rotaiy swaging, radial forging or the like. For instance, one or a plurality of dies having the specified profile of the crush guide interface 808 are engaged against the base tube 800. In one example, the one or plurality of dies include various profiles corresponding to portions of the crush guide interface such as, the guide collar 816, the recess collar 810, or one or more of the joints 812, 814, 818. A cam, pressure rollers or the like drive the dies into engagement with the base tube 800. Through prolonged or repeated engagement (e.g., compression, striking, hammering, driving or the like) of the base tube 800 by the dies the profile of the crush guide interface 808 is imparted and the crash guiding tube assembly 802 is formed.

Figure 9 shows one example of a method 900 for guiding crashing of a crush guiding tube assembly, such as the crush guiding tube assembly 104 previously described and shown herein. In describing the method 900, reference is made to one or more components, features, functions or the like described herein. W here convenient, reference is made to the components, features, functions or the like with reference numerals. Reference numerals provided are exemplary and are not exclusive. For instance, the components, features, functions or the like described in the method 900 include, but are not limited to, the corresponding numbered elements, other corresponding features described herein, both numbered and unnumbered as well as their equivalents.

At 902 the method 900 includes transmitting a crush force along the tube assembly 104. In one example, the crush force is a force or component of force (e.g., of a force at an angle to the tube assembly 104) equal to or greater than the yield strength of the assembly 104. As previou sly described herein, the crush guiding tube assembly 104 includes large and small profile tube portions 200, 202 as shown, for instance, in Figure 2. The small profile tube portion 202 has a smaller profile relative to the large profile tube portion 200 including, but not limited to, one or more diameter, shape, perimeter or the like. In another example, the crush force directed along the crush guiding tube assembly 104 includes a force aligned with a longitudinal tube axis 204 shown in Figure 2. In another example, the crash force includes a force misaligned, for instance, at an angle relative to the longitudinal tube axis 204. Accordingly, one or more of collisions or other force generating events that direct a crushing force along the crash guiding tube assembly 104, whether aligned with the longitudinal tube axis 204 or at an angle relative to the longitudinal tube axis 204 (including one or more of angles such as 5 degrees or less, 10 degrees or less, 15 degrees or less, 20 degrees or less, 25 degrees or less, 30 degrees or less or the like), are configured to crush the crush guide interface such as the interface 106 shown in Figure 2 in a manner as described herein.

At 904 the method 900 includes guiding the small profile tube portion 202 into the large profile tube portion 200 during deformation and crushing of the crush guiding tube assembly 104. In one example, guiding of the small profile tube portion 202 includes at 906 plastically deforming at least the crush guide interface 106 interposed between the large and small profile tube portions 200, 202. In another example, guiding the small profile tube portion 202 into the large profile tube portion 200 includes at 908 directing the small profile tube portion 202 into the large profile tube portion 200 according to at least a taper of a guide collar such as the guide collar 208 shown in Figure 2,

As previously described, the guide collar 208 provides a tapered interface between the small profile tube portion 202 and the large profile tube portion 200 that tapers inwardly, for instance, toward the longitudinal tube axis 204. The taper of the guide collar 208 is, in one example, increased enhanced the like during crushing at the crush guide interface 106. For instance, where the crush guide interface 106 includes the recess collar 206 (see Figure 2), the recess collar 206 is inwardly rotated during crushing by the initial movement of the small profile tube portion 202 and the guide collar 208 toward the large profile tube portion 200. The recess collar 206 is rotated inwardly by the guide collar 208 and the small profile tube portion 202, and a guide joint 212 at the end of the recess collar 206 is moved inwardly relative to the longitudinal tube axis 204. Movement of the recess collar 206 and the guide joint 2 2 contracts the guide joint 212 into a closer position relative to the longitudinal tube axis 204. The guide collar 208 follows the movement of the guide joint 212 and accordingly deforms, for instance, into an enhanced taper including increased direction toward the longitudinal tube axis 204, This deformation enhances guidance of the small profile tube portion 202 by further directing translation of the small profile tube portion 202 toward the large profile tube portion 200, for instance and the longitudinal tube axis 204. Stated another way, the small profile tube portion 202 is more centrally directed relative to the large profile tube portion 200 and accordingly one or more of misalignment, buckling or the like of the small profile tube portion 202 relative to the large profile tube portion 200 is minimized (e.g., eliminated, minimized or the like).

At 910 the small profile tube portion 202 shown in Figure 2 is, in one example, captured within the large profile tube portion 200. For instance, as previously described herein, the crush guide interface 106 plastically deforms (e.g., yields, folds, crushes, crumples or the like) during a crushing event and accordingly guides the small profile tube portion 202 into the large profile tube portion 200. In one example, the guided small profile tube portion 202 is held within the large profile tube portion 200 according to the mechanical characteristics and deformed structure of the crush guide interface 106. For instance, with plastic deformation of the crush guide interface 106, the small profile tube portion 202 is received within the large profile tube portion 200. The crush guide interface 106 including, for instance, one or more mechanical characteristics of the crush guide interface 106 including yield strength, ultimate strength or the like provide a robust and interface 106 and maintains the small profile tube portion 202 in the captured configuration therein. Additionally, the deformation of the crush guide interface 106 during the crushing event, for instance, including prolapse of one or more components of the crush guide interface 106 from the configuration shown in Figure 2 to, for instance, one or more of the configurations shown in Figures 4, 5A or 5B provides one or more mechanical features including, but not limited to, the recess collar 206 rotated into a position that intercepts the small profile tube portion 202 and prevents its escape or decoupling from the large profile tube portion 200. This arrangement as shown, for instance, in Figures 5 A and 5B provides a telescoping capture of the smal l profile tube portion 202 within the large profile tube portion 200, The telescopic capture (shown in Figures 5A and 5B) prevents the small profile tube portion 202 from backing out, decoupling or the like relative to the large profile tube portion 200.

Several options for the method 900 follow. In one example, guiding the smal l profile tube portion 202 includes maintaining the taper of the guide collar 204 during transmission of the crushing force, for instance, during a collision or crushing event with the crush guiding tube assembly 104. In another example, guiding the small profile tube portion 202 into the large profile tube portion 200 includes increasing the taper of the guide collar 208 toward at least one or more of the longitudinal tube axis such as the axis 204 shown in Figures 4, 5A, 5B or toward the large profile tube portion 200. For instance, as shown in Figures 4, 5 A and 5B, the taper of the guide col lar 208 increases with the crushing event and deformation of the crush guide interface 106.

In another example, the method 900 includes rapturing the crush guiding tube assembly 104 after capture of the small profile tube portion 202 within the large profile tube portion 200. As shown, for instance, in Figures 6A and 6B, rupture, in one example, is preferentially disposed at the crush guide interface 106, As previously described herein, the plastic deformation at the recess collar 206 as well as the decreased wall thickness corresponding to the first wall thickness 300 at the recess collar 206 relative to the second wall thickness 302 preferentially localizes stress at the recess collar 206. Accordingly, in the configuration shown, for instance, in Figure 6 A, after deformation of the recess collar 206 and of the crash guide interface 106 generally, the recess collar 206 i s configured to separate, for instance, into the opposed components shown in Figures 6 A and 6B. The recess collar 206 associated with the large profile tube portion 200 provides a capture flange or other feature configured to mechanically engage with the corresponding portion of the recess collar 206 associated with the small profile tube portion 202. The mechanical engagement between these features including each of the components of the recess collar 206 substantially prevents the backing out or decoupling of the small profile tube portion 202 from the large profile tube portion 200 after reception within the tube portion 200. Accordingly, even with rupture of the crush guiding tube assembly 104, the small profile tube portion, once received within the large profile tube portion 200, is reliably and consistently retained therein and accordingly one or more of buckling, decoupling or the li ke of the small profile tube portion 202 from the large profile tube portion 200 is prevented (e.g., including minimized, eliminated or the like) during a collision or crushing event.

In still another example, guiding the small profile tube portion 202 into the large profile tube portion 200 includes expanding the large profile tube portion 200 adjacent to the crush guide interface 106 relative to the remainder of the large profile tube portion 200. As shown in Figure 4, in one example, the large interface joint 210 includes a large profile trumpet 404 providing an enhanced profile relative to the remainder of the large profile tube portion 200. The large profile trumpet 204 is biased outwardly, for instance, by the deformation at the crush guiding interface 106. For instance, the movement of the small profile tube portion 202 and the folding or crumpling at the crush guide interface 106 biases the portion of the large profile tube portion 200 proximate to the large interface joint 210 in an outward fashion to accordingly provide a bell or trumpet shape that further enhances guidance of the small profile tube portion 202 into the interior of the large profile tube portion 200.

In another example, plastic deformation at the crush guide interface 106 optionally includes generating one or more composite radii at the crash guide interface 106 to accordingly promote plastic deformation while minimizing the possibility of rupture at the crush guide interface 106 at least prior to reception and capture of the small profile tube portion 202 within the large profile tube portion 200. Referring to Figure 5B, a tear drop profile 506 is optionally provided at the crush guide interface 106 in the crushed configuration. In one example, the tear drop profile 506 optionally includes a composite bend radius 500 including a plurality of component bend radii 502, 504 corresponding to components of the crush guide interface 106 in a deformed configuration during crushing. In one example, the components included in the tear drop profile include, one or more of the guide joint 212, the recess collar 206, the small interface joint 214 and the adjacent components of the crush guide interface (including the large interface joint 210, the guide collar 208 and the like). The relatively large radius of the composite bend radius 500 of the tear drop profile 506 distributes stresses across the crush guide interface 106 and accordingly minimizes stresses at one or more locations that would otherwise precipitate rupture of the crash guide interface 106 prior to reception and capture of the small profile tube portion 202 within the large profile tube portion 200. Accordingly, the small profile tube portion 202, including the tear drop profile 506 or the composite bend radius 500 described herein, is configured to reliably receive and capture the small profile tube portion 202 within the large profile tube portion 200 before rupture in the crush guiding tube assembly 104.

For instance, as shown in Figures 6A and 6B, rupture in the crush guiding tube assembly 104 is minimized by the tear drop profile 506 shown in Figure 5B until at least the small profile tube portion 202 is received within the large profile tube portion 200. After reception therein and capture of the small profile tube portion 202, in some examples, with additional deformation of the crash guiding tube assembly 104, the small profile tube portion 202 ruptures (e.g., splits, fractures or the like) relative to the large profile tube portion 200. However, the small profile tube portion 202 remains captured within the large profile tube portion 200 even with rupturing according to capture provided by the crush guide interface 106.

Various Notes and Examples

Example 1 can include subject matter such as a crush guiding tube assembly comprising: a large profile tube portion extending along a longitudinal tube axis; a small profile tube portion extending along the longitudinal tube axis, the small profile tube portion is smaller than the large profile tube portion; and a crush guide interface coupled between the large and small profile tube portions, the crush guide interface includes: a recess collar extending inwardly toward the longitudinal tube axis from a large interface joint of the large profile tube portion to a guide joint, a guide collar tapering inwardly toward the longitudinal tube axis from a small interface joint of the small profile tube portion to the guide joint, and the guide collar extends toward the large profile tube portion, and wherein the guide collar tapers inwardly according to the recessing of the guide joint from the large profile tube portion.

Example 2 can include, or can optionally be combined with the subject matter of Example 1, to optionally include wherein the guide joint includes a guide joint profile smaller than both of the large and small profile tube portions.

Example 3 can include, or can optionally be combined with the subject matter of one or any combination of Examples 1 or 2 to optionally include wherein the small profile tube portion includes a small profile diameter and the large profile tube portion includes a large profile diameter, and the small profile diameter is ninety one percent or less of the large profile diameter.

Example 4 can include, or can optionally be combined with the subject matter of one or any combination of Examples 1-3 to optionally include wherein the small profile tube portion includes a small profile outer diameter and the large profile tube portion includes a large profile inner diameter, and the small profile outer diameter is smaller than the large profile inner diameter.

Example 5 can include, or can optionally be combined with the subject matter of one or any combination of Examples 1-4 to optionally include wherein each of the large and small profile tube portions and the crash guide interface have a consistent yield strength.

Example 6 can include, or can optionally be combined with the subject matter of Examples 1 -5 to optionally include wherein the large profile tube portion has a first wall thickness and the small profile tube portion and the crush guide interface have a second wall thickness greater than the first wall thickness.

Example 7 can include, or can optionally be combined with the subject matter of Examples 1 -6 to optionally include wherein each of the large and small profile tube portions and the crush guide interface are aligned with the longitudinal tube axis.

Example 8 can include, or can optionally be combined with the subject matter of Examples 1-7 to optionally include wherein the crush guide interface includes a working configuration and a crushing configuration; in the working configuration the recess collar is at a first recess angle relative to the large profile tube portion, the guide collar is at a first guide angle relative to the small profile tube portion, and the guide joint is at a first joint position relative to the longitudinal tube axis, and in the crushing configuration the recess collar is at a second recess angle greater than the first recess angle, the guide collar is at a second guide angle greater than the first guide angle, and the guide joint is at a second joint position closer to the longitudinal tube axis than the first joint position.

Example 9 can include, or can optionally be combined with the subject matter of Examples 1 -8 to optionally include wherein a transition from the working configuration to the crushing configuration includes continuous annular plastic deformation of the crush guide interface.

Example 10 can include, or can optionally be combined with the subject matter of Examples 1 -9 to optionally include wherein in the crushing configuration one or more of the recess collar or the guide collar guides the crush guide interface into an expanding configuration with the crush guide interface expanding to a tear drop profile.

Example 11 can include, or can optionally be combined with the subject matter of Examples 1 -10 to optionally include a crush guiding tube assembly comprising: a large profile tube portion extending along a longitudinal tube axis; a small profile tube portion extending along the longitudinal tube axis, the small profile tube portion is smaller than the large profile tube portion; a crush guide interface between the large and small profile tube portions, the crash guide interface includes a guide collar tapering from a small interface joint at the small profile tube portion toward a guide joint near the large profile tube portion, and the guide joint has a guide joint profile smaller than the large and small profile tube portions; and wherein the crush guide interface includes working and crushing configurations: in the working configuration the guide collar tapers toward the longitudinal tube axis at a first guide angle relative to the small profile tube portion, and in the crushing configuration the guide collar tapers toward the longitudinal tube axis at a second guide angle greater than the first guide angle.

Example 12 can include, or can optionally be combined with the subject matter of Examples 1-11 to optionally include wherein a transition from the working configuration to the crashing configuration includes continuous annular plastic deformation of the crush guide interface.

Example 13 can include, or can optionally be combined with the subject matter of Examples 1-12 to optionally include wherein the crush guide interface includes a captured configuration, and in the captured configuration: at least a portion of the small profile tube portion is telescopically received in the large profile tube portion according to the taper of the guide collar, and the portion of the small profile tube portion is captured within the large profile tube portion.

Example 14 can include, or can optionally be combined with the subject matter of Examples 1 -13 to optionally include wherein the captured configuration includes a rupture between the small profile tube portion and the large profile tube portion within the large profile tube portion.

Example 15 can include, or can optionally be combined with the subject matter of Examples 1-14 to optionally include wherein in the captured configuration one or more of the recess collar or the guide collar guides the crash guide interface into an expanding configuration with the crash guide interface expanding to a tear drop profile. Example 16 can include, or can optionally be combined with the subject matter of Examples 1-15 to optionally include wherein the small profile tube portton includes a small profile diameter and the large profile tube portion includes a large profile diameter, and the small profile diameter is ninety one percent or less of the large profile diameter.

Example 17 can include, or can optionally be combined with the subject matter of Examples 1-16 to optionally include wherein the small profile tube portton includes a small profile outer diameter and the large profile tube portion includes a large profile inner diameter, and the small profile outer diameter is smaller than the large profile inner diameter.

Example 18 can include, or can optionally be combined with the subject matter of Examples 1-17 to optionally include wherein each of the large and small profile tube portions and the crush guide interface have a consistent yield strength.

Example 19 can include, or can optionally be combined with the subject matter of Examples 1-18 to optionally include wherein the large profile tube portion has a first wall thickness and the small profile tube portion and the crush guide interface have a second wail thickness greater than the first wall thickness.

Example 20 can include, or can optionally be combined with the subject matter of Examples 1-19 to optionally include wherein the crush guide interface includes a recess collar extending inwardly from the large profile tube portion to the guide joint.

Example 21 can include, or can optionally be combined with the subject matter of Examples 1 -20 to optionally include wherein in the working configuration the guide joint is at a first joint position relative to the longitudinal tube axis according to a first recess angle of the recess collar, and in the crushing

configuration recess collar is rotated inwardly to a second recess angle greater than the first recess angle, and the guide joint is at a second joint position closer to the longitudinal tube axis than the first joint position according to the rotation of the recess collar. Example 22 can include, or can optionally be combined with the subject matter of Examples 1-21 to optionally include wherein in the crushing configuration the large profile tube portion proximate to the recess collar is expanded relative to the remainder of the large profile tube portion.

Example 23 can include, or can optionally be combined with the subject matter of Examples 1-22 to optionally include a method for guiding crushing of a crush guiding tube assembly comprising: transmitting a crush force along the tube assembly including large and small profile tube portions, the small profile tube portion is smaller than the large profile tube portion, guiding the small profile tube portion into the large profile tube portion including: plastically deforming at least a crush guide interface interposed between the large and small profile tube portions, and directing the small profile tube portion into the large profile tube portion according to at least a taper of a guide collar of the plastically deformed crush guide interface; and capturing the small profile tube portion within the large profile tube portion with the plastically deformed crush guide interface,

Example 24 can include, or can optionally be combined with the subject matter of Examples 1-23 to optionally include wherein guiding the small profile tube portion includes maintaining the taper of the guide collar during transmission of the crushing force.

Example 25 can include, or can optionally be combined with the subject matter of Examples 1-24 to optionally include wherein guiding the small profile tube portion includes increasing the taper of the guide collar toward a longitudinal tube axis of at least the large profile tube portion during transmission of the crushing force.

Example 26 can include, or can optionally be combined with the subject matter of Examples 1-25 to optionally include wherein guiding the small profile tube portion includes telescopically receiving the small profile tube portion in the large profile tube portion. Example 27 can include, or can optionally be combined with the subject matter of Examples 1-26 to optionally include rupturing of the crush guiding tube assembly after capture of the small profile tube portion within the large profile tube portion.

Example 28 can include, or can optionally be combined with the subject matter of Examples 1-27 to optionally include wherein rupturing is at the crush guide interface.

Example 29 can include, or can optionally be combined with the subject matter of Examples 1 -28 to optionally include wherein plastically deforming at least the crush guide interface includes increasing a taper of the guide collar toward a longitudinal tube axis of at least the large profile tube portion.

Example 30 can include, or can optionally be combined with the subject matter of Examples 1 -29 to optionally include wherein plastically defomiing at least the crush guide interface includes: rotating a recess collar of the caish guide interface inwardly toward a longitudinal tube axis of at least the large profile tube portion, and moving a guide joint between the recess collar and the guide collar inwardly toward the longitudinal tube axis and correspondingly increasing a taper of the guide collar according to the rotation of the recess collar.

Example 31 can include, or can optionally be combined with the subject matter of Examples 1-30 to optionally include guiding the small profile tube portion into the large profile tube portion includes expanding the large profile tube portion adjacent to the crush guide interface relative to the remainder of the large profile tube portion.

Example 32 can include, or can optionally be combined with the subject matter of Examples 1-31 to optionally include wherein plastically deforming at least the crush guide interface includes generating a tear drop profile in the crush guide interface.

Example 33 can include, or can optionally be combined with the subject matter of Examples 1-32 to optionally include a method for making a crush guiding tube assembly comprising: forming a multiple profile intermediate tube assembly including a large profile tube portion, a small profile tube portion and an intermediate interface therebetween, the small profile tube portion smaller than the large profile tube portion; and deforming the intermediate interface to form a crush guide interface between the large and small profile tube portions, deforming includes: inwardly deforming an interface root of the intermediate interface to form a recess collar of the crush guide interface, the interface root proximate the large profile tube portion and remote relative to the small profile tube portion, and deflecting an interface end of the intermediate interface according to the inward deforming of the interface root, the interface end is proximate the small profile tube portion and remote relative to the large profile tube portion, wherein deflection of the interface end forms a guide collar of the crush guide interface.

Example 34 can include, or can optionally be combined with the subject matter of Examples 1 -33 to optionally include wherein forming the multiple profile intermediate tube assembly includes end forming an isodiametric base tube.

Example 35 can include, or can optionally be combined with the subject matter of Examples 1-34 to optionally include wherein one or more of forming the multiple profile intermediate tube assembly and deforming the intermediate interface includes push forming, internal expansion, rotary swaging, radial forging, spin forming or hydroforming.

Example 36 can include, or can optionally be combined with the subject matter of Examples 1 -35 to optionally include wherein an interm ediate taper of the intermediate interface widens from the small profile tube portion toward the large profile tube portion, and deforming the intermediate interface to form the crush guide interface includes inverting the intermediate taper of the intermediate interface into a taper of the guide collar that narrows from the small profile tube portion toward the large profile tube portion. Example 37 can include, or can optionally be combined with the subject matter of Examples 1-36 to optionally include wherein inwardly deforming the interface root includes end forming the interface root.

Example 38 can include, or can optionally be combined with the subject matter of Examples 1 -37 to optionally include wherein deflecting the interface end according to the inward deforming of the interface root includes bowing the intermediate interface from the interface end to the recess collar according to the stiffness of the of the intermediate interface.

Example 39 can include, or can optionally be combined with the subject matter of Examples 1-38 to optionally include wherein bowing the intermediate interface includes bowing the intermediate interface around a die that performs the inward deforming of the interface root.

Example 40 can include, or can optionally be combined with the subject matter of Examples 1 -39 to optionally include wherein each of forming the multiple profile intermediate tube assembly and deforming the intermediate interface includes plastic deformation while blocking annealing.

Example 41 can include, or can optionally be combined with the subject matter of Examples 1 -40 to optionally include wherein inwardly deforming the interface root includes forming the recess collar at an acute recess angle relative to the large profile tube portion.

Example 42 can include, or can optionally be combined with the subject matter of Examples 1 -41 to optionally include wherein deflecting the interface end includes forming the guide collar with an acute guide angle relative to the small profile tube portion.

Each of these non-limiting examples can stand on its own, or can be combined in various permutations or combinations with one or more of the other examples.

The above detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the disclosure can be practiced. These embodiments are also referred to herein as "examples." Such examples can include elements in addition to those shown or described. However, the present inventors also contemplate examples in which only those elements shown or described are provided. Moreover, the present inventors also contemplate examples using any combination or permutation of those elements shown or described (or one or more aspects thereof), either with respect to a particular example (or one or more aspects thereof), or with respect to other examples (or one or more aspects thereof) shown or described herein.

In the event of inconsistent usages between this document and any documents so incorporated by reference, the usage in this document controls.

In this document, the terms "a" or "an" are used, as is common in patent documents, to include one or more than one, independent of any other instances or usages of "at least one" or "one or more." In this document, the term "or" is used to refer to a nonexclusive or, such that "A or B" includes "A but not B," "B but not A," and "A and B," unless otherwise indicated. In this document, the terms "including" and "in which" are used as the plain-English equivalents of the respective terms "comprising" and "wherein," Also, in the following claims, the terms "including" and "comprising" are open-ended, that is, a system, device, article, composition, formulation, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim. Moreover, in the following claims, the terms "first," "second," and "third," etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.

The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) may be used in combination with each other. Other embodiments can be used, such as by one of ordinary skill in the art upon reviewing the above description. The Abstract is provided to comply with 37 C.F.R. § 1.72(b), to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description as examples or embodiments, with each claim standing on its own as a separate embodiment, and it is contemplated that such embodiments can be combined with each other in various combinations or permutations. The scope of the disclosure should be detennined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

Claims

THE CLAIMED INVENTION IS:

1. A crush guiding tube assembly comprising:

a large profile tube portion extending along a longitudinal tube axis;

a small profiie tube portion extending along the longitudinal tube axis, the small profile tube portion is smaller than the large profile tube portion; and

a crush guide interface coupled between the large and small profile tube portions, the crush guide interface includes:

a recess collar extending inwardly toward the longitudinal tube axis from a large interface joint of the large profile tube portion to a guide joint, a guide collar tapering inwardly toward the longitudinal tube axis from a small interface joint of the small profile tube portion to the guide joint, and the guide collar extends toward the large profile tube portion, and wherein the guide collar tapers inwardly according to the recessing of the guide joint from the large profile tube portion.

2. The assembly of claim 1, wherein the guide joint includes a guide joint profile smaller than both of the large and small profile tube portions,

3. The assembly of claim 1, wherein the small profile tube portion includes a small profile diameter and the large profile tube portion includes a large profile diameter, and the small profiie diameter is ninety one percent or less of the large profile diameter.

4. The assembly of claim 1 , wherein the small profile tube portion includes a small profile outer diameter and the large profile tube portion includes a large profile inner diameter, and the small profile outer diameter is smaller than the large profile inner diameter.

5. The assembly of claim 1, wherein each of the large and small profile tube portions and the crush guide interface have a consistent yield strength.

6. The assembly of claim 1, wherein the large profile tube portion has a first wall thickness and the small profile tube portion and the crush guide interface have a second wall thickness greater than the first wall thickness.

7. The assembly of claim 1, wherein each of the large and small profile tube portions and the crush guide interface are aligned with the longitudinal tube axis,

8. The assembly of claim 1, wherein the crush guide interface includes a working configuration and a crushing configuration:

in the working configuration the recess collar is at a first recess angle relative to the large profile tube portion, the guide collar is at a first guide angle relative to the small profile tube portion, and the guide joint is at a first joint position relative to the longitudinal tube axis, and

in the crushing configuration the recess collar is at a second recess angle greater than the first recess angle, the guide collar is at a second guide angle greater than the first guide angle, and the guide joint is at a second joint position closer to the longitudinal tube axis than the first joint position.

9. The assembly of claim 8, wherein a transition from the working

configuration to the crushing configuration includes continuous annular plastic deformation of the crush guide interface.

10. The assembly of claim 8, wherein in the crushing configuration one or more of the recess collar or the guide collar guides the crush guide interface into an expanding configuration with the crush guide interface expanding to a tear drop profile.

1 1 . A crush guiding tube assembly comprising:

a large profile tube portion extending along a longitudinal tube axis;

a small profile tube portion extending along the longitudinal tube axis, the small profile tube portion is smaller than the large profile tube portion;

a crush guide interface between the large and small profile tube portions, the crush guide interface includes a guide collar tapering from a small interface joint at the small profile tube portion toward a guide joint near the large profile tube portion, and the guide joint has a guide joint profile smaller than the large and small profile tube portions; and

wherein the crush guide interface includes working and crushing

configurations:

in the working configuration the guide collar tapers toward the longitudinal tube axis at a first guide angle relative to the small profile tube portion, and

in the crashing configuration the guide collar tapers toward the longitudinal tube axis at a second guide angle greater than the first guide angle.

12. The assembly of claim 11, wherein a transition from the working

configuration to the caishing configuration includes continuous annular plastic deformation of the crush guide interface.

13. The assembly of claim 11, wherein the crush guide interface includes a captured configuration, and in the captured configuration:

at least a portion of the small profile tube portion is telescopically received in the large profile tube portion according to the taper of the guide collar, and the portion of the small profile tube portion is captured within the large profile tube portion,

14. The assembly of claim 13, wherein the captured configuration includes a rupture between the small profile tube portion and the large profile tube portion within the large profile tube portion.

15. The assembly of claim 13, wherein in the captured configuration one or more of the recess collar or the guide collar guides the crush guide interface into an expanding configuration with the crush guide interface expanding to a tear drop profile.

16. The assembly of claim 1 1, wherein the small profile tube portion includes a small profile diameter and the large profile tube portion includes a large profile diameter, and the small profile diameter is ninety one percent or less of the large profile diameter.

17. The assembly of claim 11 , wherein the small profile tube portion includes a small profile outer diameter and the large profile tube portion includes a large profile inner diameter, and the small profile outer diameter is smaller than the large profile inner diameter.

18. The assembly of claim 11, wherein each of the large and small profile tube portions and the crush guide interface have a consistent yield strength.

19. The assembly of claim 1 1, wherein the large profile tube portion has a first wall thickness and the small profile tube portion and the crush guide interface have a second wall thickness greater than the first wall thickness.

20. The assembly of claim 11, wherein the crush guide interface includes a recess collar extending inwardly from the large profile tube portion to the guide joint.

21. The assembly of claim 20, wherein

in the working configuration the guide joint is at a first joint position relative to the longitudinal tube axis according to a first recess angle of the recess collar, and

in the crushing configuration recess collar is rotated inwardly to a second recess angle greater than the first recess angle, and the guide joint is at a second joint position closer to the longitudinal tube axis than the first joint position according to the rotation of the recess collar.

22. The assembly of claim 11, wherein in the crushing configuration the large profile tube portion proximate to the recess collar is expanded relative to the remainder of the large profile tube portion,

23. A method for guiding crashing of a crush guiding tube assembly comprising: transmitting a crush force along the tube assembly including large and small profile tube portions, the small profile tube portion is smaller than the large profile tube portion;

guiding the small profile tube portion into the large profile tube portion including:

plastically deforming at least a crush guide interface interposed between the large and small profile tube portions, and

directing the small profile tube portion into the large profile tube portion according to at least a taper of a guide collar of the plastically deformed caish guide interface; and capturing the small profile tube portion within the large profile tube portion with the plastically deformed crush guide interface.

24. The method of claim 23, wherein guiding the small profile tube portion includes maintaining the taper of the guide collar during transmission of the crushing force.

25. The method of claim 23, wherein guiding the small profile tube portion includes increasing the taper of the guide collar toward a longitudinal tube axis of at least the large profile tube portion during transmission of the crushing force.

26. The method of claim 23, wherein guiding the small profile tube portion includes telescopically receiving the small profile tube portion in the large profile tube portion.

27. The method of claim 23 comprising rupturing of the crush guiding tube assembly after capture of the small profile tube portion within the large profile tube portion,

28. The method of claim 27, wherein rupturing is at the crush guide interface.

29. The method of claim 23, wherein plastically deforming at least the crush guide interface includes increasing a taper of the guide collar toward a longitudinal tube axis of at least the large profile tube portion.

30. The method of claim 23, wherein plastically deforming at least the crush guide interface includes:

rotating a recess collar of the crush guide interface inwardly toward a longitudinal tube axis of at least the large profile tube portion, and moving a guide joint between the recess collar and the guide collar inwardly toward the longitudinal tube axis and correspondingly increasing a taper of the guide collar according to the rotation of the recess collar.

31. The method of claim 23, guiding the small profile tube portion into the large profile tube portion includes expanding the large profile tube portion adjacent to the crush guide interface relative to the remainder of the large profile tube portion.

32. The method of claim 23, wherein plastically deforming at least the crush guide interface includes generating a tear drop profile in the crush guide interface.

33. A method for making a crush guiding tube assembly comprising:

forming a multiple profile intermediate tube assembly including a large profile tube portion, a small profile tube portion and an intermediate interface therebetween, the small profile tube portion smaller than the large profile tube portion; and

deforming the intermediate interface to form a crush guide interface between the large and small profile tube portions, deforming includes:

inwardly deforming an interface root of the intermediate interface to form a recess collar of the crush guide interface, the interface root proximate the large profile tube portion and remote relative to the small profile tube portion, and

deflecting an interface end of the intermediate interface according to the inward deforming of the interface root, the interface end is proximate the small profile tube portion and remote relative to the large profile tube portion, wherein deflection of the interface end forms a guide collar of the crush guide interface.

34. The method of claim 33, wherein forming the multiple profile intermediate tube assembly includes end forming an isodiametric base tube.

35. The method of claim 33, wherein one or more of forming the multiple profile intermediate tube assembly and deforming the intermediate interface includes push forming, internal expansion, rotary swaging, radial forging, spin forming or hydroforming.

36. The method of claim 33, wherein an intermediate taper of the intermediate interface widens from the small profile tube portion toward the large profile tube portion, and

deforming the intermediate interface to form the crush guide interface includes inverting the intermediate taper of th e intermediate interface into a taper of the guide collar that narrows from the small profile tube portion toward the large profile tube portion.

37. The method of claim 33, wherein inwardly deforming the interface root includes end forming the interface root.

38. The method of claim 33, wherein deflecting the interface end according to the inward deforming of the interface root includes bowing the intermediate interface from the interface end to the recess collar according to the stiffness of the of the intermediate interface.

39. The method of claim 38, wherein bowing the intermediate interface includes bowing the intermediate interface around a die that performs the inward deforming of the interface root.

40. The method of claim 33, wherein each of forming the multiple profile intermediate tube assembly and deforming the intermediate interface includes plastic deformation while blocking annealing.

41. The method of claim 33, wherein inwardly deforming the interface root includes forming the recess collar at an acute recess angle relative to the large profile tube portion,

42. The method of claim 33, wherein deflecting the interface end includes forming the guide collar with an acute guide angle relative to the small profile tube portion.