Structural beam and method of manufacture thereof
AssigneeNorsk Hydro a.s.
InventorEdvin L. Clausen
Life of this patent
Estimating the term…
Abstract
A structural beam, particularly for use as a door pillar or a bumper of a motor vehicle, includes a one-piece elongated extruded member formed of a light metal. The member has therethrough an elongated, laterally enclosed cavity defined by elongated side walls including at least two generally parallel side walls. A deformation pressure is applied to walls extending generally transverse to the two side walls, with the result that there occurs controlled folding of the two side walls with the formation therein of folds that extend parallel to the direction of elongation of the member. Thus, the cross-sectional area of the cavity through the member is reduced.
Claims40
A structural beam for use as a structural part of a motor vehicle, said structural beam comprising:
- a one-piece elongated extruded member formed of an aluminum alloy;
- said member having therethrough an elongated, laterally enclosed cavity defined by elongated side walls of said member including at least one pair of opposed, laterally spaced said side walls;
- said member having a transverse cross-sectional configuration that is continuous and seamless annularly;
- and
- said member having at least one length portion whereat said cavity has a transverse cross-sectional area that is reduced compared to the cross-sectional area of at least one other portion of the length of said member, whereat at least portions of said one pair of side walls are of a wall thickness that is reduced compared to other of said side walls, and whereat said portions of said two side walls of reduced wall thickness have formed therein folds that extend parallel to a direction of elongation of said member, thereby defining a reduced dimension of said member in a direction transverse to said direction of elongation.
A door pillar to be used in a space frame of a motor vehicle, said door pillar having upper and lower ends to be connected to the space frame, said door pillar comprising:
- a one-piece elongated extruded member formed of an aluminum alloy;
- said member having therethrough an elongated, laterally enclosed cavity defined by elongated side walls of said member including first and second pairs of opposed, laterally spaced said side walls, said first pair of side walls extending transversely of said second pair of side walls;
- said member having a transverse cross-sectional configuration that is continuous and seamless annularly;
- said member having an upper length portion whereat said cavity has a transverse cross-sectional area that is reduced compared to the cross-sectional area of the remainder of the length of said member and whereat said first pair of side walls have formed therein folds that extend parallel to a direction of elongation of said member, thereby defining a reduced dimension of said upper length portion of said member in a direction transverse to said direction of elongation;
- and
- said reduced dimension of said upper length portion of said member reducing gradually from said remainder of the length of said member to said upper end of said door pillar.
A method of manufacture of a structural beam for use as a structural part of a motor vehicle, said method comprising:
- applying a deformation pressure to at least one length portion of a one-piece elongated extruded member formed of an aluminum alloy and having therethrough an elongated, laterally enclosed cavity defined by elongated side walls including at least one pair of opposed, laterally spaced said side walls that have portions that are of a wall thickness that is reduced compared to other of said side walls, said member having a transverse cross-sectional configuration that is continuous and seamless annularly;
- and
- said deformation pressure being applied to said length portion in a direction transverse to a direction of elongation of said member and parallel to a width dimension of said one pair of side walls, thereby causing formation, in said reduced wall thickness portions of said one pair of side walls of said at least one length portion, of folds that extend parallel to said direction of elongation, a reduction of transverse cross-sectional area of said cavity in said at least one length portion compared to at least one other portion of the length of said member, and a reduction of the dimension of said member in said direction of application of said deformation pressure.
A method of manufacture of a door pillar having upper and lower ends to be connected to a space frame of a motor vehicle, said method comprising:
- applying a deformation pressure to an upper length portion of a one-piece elongated extruded member formed of an aluminum alloy and having therethrough an elongated, laterally enclosed cavity defined by elongated side walls including first and second pairs of opposed, laterally spaced said side walls with said first pair of side walls extending transversely of said second pair of side walls, said member having a transverse cross-sectional configuration that is continuous and seamless annularly;
- said deformation pressure being applied to said upper length portion in a direction transverse to a direction of elongation of said member and parallel to a width dimension of said first pair of side walls, thereby causing formation in said first pair of side walls of folds that extend parallel to said direction of elongation, a reduction of transverse cross-sectional area of said cavity in said upper length portion compared to the remainder of the length of said member, and a reduction of the dimension of said upper length portion of said member in said direction of application of said deformation pressure;
- and
- said deformation pressure being applied such that said reduction of dimension of said upper length portion of said member is gradual from said remainder of the length of said member to said upper end of said door pillar.
Dependencies are inferred from the claim text.