Tubular rack beam and method of making same

Abstract

A hollow, tubular beam is formed of an outer and an inner, U-shaped, elongated, roll-formed, sheet metal channel which are telescopically interfitted. The overlapping adjacent leg portions of each channel are provided with an inwardly bent rib and groove mechanical connection, but the curvature of the adjacent rib and groove surfaces are slightly different to provide a number of longitudinally extending, separated spaces therebetween. The free edge of one of the legs of the outer channel is bent normally to cover a corresponding corner-like shoulder bent in the adjacent inner channel leg. The radii of the flange and shoulder bends are slightly different to provide a slight, longitudinally extending space between them. Also, overlapping leg portions are spaced apart by integral embossments formed on the legs. The adjacent channel legs are adhesively bonded together by an adhesive material applied within the spaces.

Dependencies are inferred from the claim text.