# US 2006/0185636 A1 · Manufacturing a rocker lever using cold forming and welding

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- Number: US 2006/0185636 A1
- Document ID: US20060185636A1
- Status: Published application
- Kind: A1
- Application number: 11/063,915
- Filed: 2005-02-23
- Published: 2006-08-24
- Earliest claimed: 2005-02-23
- Assignees: Gen Tek Technologies Marketing, Inc.
- Inventors: John Brune; Scott Smith
- Web page: https://patentgrep.com/patent/US20060185636A1

## CPC

- F01L 1/181: {Centre pivot rocking arms}
- F01L 1/146: {Push-rods}
- F01L 2001/2427: {by means of an hydraulic adjusting device located between cam and push rod}
- F01L 2303/00: Manufacturing of components used in valve arrangements
- F01L 2305/00: Valve arrangements comprising rollers
- Y10T 29/49231: I.C. [internal combustion] engine making
- F01L: CYCLICALLY OPERATING VALVES FOR MACHINES OR ENGINES
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A method and system for forming a rocker assembly includes cold forming a metal blank to produce a portion of the rocker assembly. This portion has a tubular portion that rotatably engages a shaft and an arm that couples with a pushrod. This portion is welded to a valve lever to form the rocker assembly.

## Claims

### Claim 1

A rocker assembly for an engine comprising:
a tubular member having a first axial end, a second axial end, and an integrally formed arm adjacent said first axial end; and
a valve lever coupled to said tubular member adjacent said second axial end and opposite of said arm.

### Claim 2 (depends on 1)

The assembly of claim 1 further comprising:
a cup formed within said arm, said cup adapted to selectively couple with a push rod.

### Claim 3 (depends on 1)

The assembly of claim 1 further comprising:
a valve contacting surface formed on said valve lever.

### Claim 4 (depends on 1)

The assembly of claim 1 wherein a side of said valve lever contacts an axial end of said tubular member.

### Claim 5 (depends on 1)

The assembly of claim 1 wherein said valve lever is coupled to said tubular member by welding.

### Claim 6 (depends on 1)

The assembly of claim 1 wherein said valve lever is coupled to said tubular member by laser welding.

### Claim 7 (depends on 1)

The assembly of claim 1 wherein said valve lever is coupled to said tubular member by electron beam welding.

### Claim 8 (depends on 1)

The assembly of claim 1 wherein said valve lever is coupled to said tubular member by pulsed plasma arc welding.

### Claim 9

A method of manufacturing a cam-engaged rocker comprising:
obtaining a metal blank, said metal blank defined, at least in part, by a first surface, an opposing second surface, a peripheral surface intersecting both said first surface and said second surface, and a projection, wherein said metal blank contains a predetermined amount of a metal; and
forming at least a portion of said metal blank by exerting a force on said metal blank adjacent said first surface, wherein a tubular portion is formed by the flow of a portion of said metal.

### Claim 10 (depends on 9)

The method of claim 9, wherein forming said metal blank includes cold forming a central portion of said metal blank.

### Claim 11 (depends on 9)

The method of claim 9, further comprising forming a cup in said projection.

### Claim 12 (depends on 9)

The method of claim 9, further comprising radially aligning a valve lever to said tubular portion.

### Claim 13 (depends on 9)

The method of claim 9, further comprising welding a valve lever to said tubular portion.

### Claim 14 (depends on 13)

The method of claim 13, wherein said welding comprises laser welding.

### Claim 15

A method of manufacturing a cam-engaged rocker comprising:
obtaining an annular metal blank, said annular metal blank defined, at least in part, by an outer cylindrical surface, an inner cylindrical surface a valve end, and a cup end, wherein said annular metal blank contains a predetermined amount of a metal; and
forming a projection on said annular metal blank by exerting a force on at least a portion of said annular metal blank adjacent said cup end, wherein a projection is formed by the flow of a portion of said metal, the projection extending from a tubular portion.

### Claim 16 (depends on 15)

The method of claim 15, further comprising:
positioning said annular metal blank adjacent a die, wherein said die includes a cavity, wherein forming the annular metal blank includes exerting a force on said annular metal blank in a predetermined direction thereby causing a flow of the metal into said cavity.

### Claim 17 (depends on 15)

The method of claim 15, further comprising forming a cup in said projection.

### Claim 18 (depends on 15)

The method of claim 15, further comprising welding a valve lever to said tubular portion.

### Claim 19 (depends on 18)

The method of claim 18, wherein said welding comprises laser welding