# US 7,761,988 B2 · Method of making an outer lever of a switchable finger lever > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 7,761,988 B2 - Document ID: US7761988B2 - Status: Granted - Kind: B2 - Application number: 10/563,850 - Filed: 2004-06-02 - Published: 2008-08-14 - Granted: 2010-07-27 - Earliest claimed: 2003-07-09 - Assignees: Schaeffler KG - Inventors: Bodo Rorig; Peter Spitzer - Web page: https://patentgrep.com/patent/US7761988B2 ## CPC - B21K 1/205: {rocker arms} - B21D 53/84: other parts for engines, e.g. connecting-rods - F01L 1/185: {Overhead end-pivot rocking arms} - F01L 13/0005: {Deactivating valves} - F01L 13/0036: {the valves being driven by two or more cams with different shape, size or timing or a single cam profiled in axial and radial direction} - F01L 2001/186: {Split rocking arms, e.g. rocker arms having two articulated parts and means for varying the relative position of these parts or for selectively connecting the parts to move in unison} - F01L 2301/00: Using particular materials - Y10T 29/49295: Push rod or rocker arm making - Y10T 29/49426: including metal shaping and diverse operation - Y10T 29/49995: Shaping one-piece blank by removing material - B21K: MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS (making particular articles by working sheet metal without essentially removing material B21D; processing wire B21F; making pins, needles or nails B21G; making particular articles by rolling B21H; forging machines, pressing machines, hammering machines, in general B21J; making chains B21L; plating B23K) - B21D: WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL (working or processing of wire B21F) - F01L: CYCLICALLY OPERATING VALVES FOR MACHINES OR ENGINES - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract According to the present invention, an outer lever (1) of a finger lever (2) that can be switched to different lifts for at least one gas exchange valve is made by a deep drawing method. A salient feature of the invention is that a cup-shaped base body (16) having an inverse U-shaped cross-section is deep drawn, and opposing running contact surfaces (14, 15) for high-lift cams are created on arms (4, 5) of the outer lever (1) by punching out a bottom (19) of the base body (16). Through the deep drawing method of the invention, only relatively low fabrication costs are to be expected. ## Claims ### Claim 1 A method of making an outer lever of a finger lever that can be switched to different lifts for at least one gas exchange valve, said outer lever comprising two substantially parallel arms whose ends are connected by crossbars so that a rectangular or O-like aperture for an inner lever that is capable of pivoting relative to the outer lever is formed, a running contact surface for a high-lift cam being arranged on an upper side of each arm said method of comprising the following work steps to which further intermediate steps may be added: a) deep drawing a cup-shaped base body our of a metal sheet or a sheet metal strip such that at least one drawing die is applied to the metal sheet or the sheet metal strip from an underside of the arms to be formed and a substantial height of the arms and the crossbars in the cup-shaped base body is produced, so that, as viewed in cross-section, an inverse U-shaped profile is formed, b) reducing a radius in the edge region between a bottom of the cup-shaped base body and outer sides of the arms by shaping, typically stamping or extrusion at least in the region of the running contact surfaces to be subsequently formed, and c) punching out the bottom of the cup-shaped base body except for at least the two opposing running contact surfaces, and wherein simultaneously with, or directly or indirectly after step a), a further step is carried out in which the drawing die or at least one further drawing die or a stamping die is applied to the bottom in deep drawing direction in a vicinity of the end, so that, one of a laterally open or closed lug-like cavity is formed, and the material of the cavity is also punched out in step c) except for an extension starting from the crossbar said one of the end, and wherein a finger pointing in a longitudinal direction of the lever is punched out of the bottom simultaneously with the running contact surfaces, which finger is bent away from the aperture in a consequent step so as to project upwards from the crossbar. ### Claim 2 (depends on 1) A method of claim 1 wherein the cavity extends from a center crossbar. ### Claim 3 (depends on 1) A method of claim 1, wherein the bottom is cut off in step c) such that inner surfaces of the arms and the crossbars, except for the running contact surfaces, merge directly or at least approximately directly into the upper sides. ### Claim 4 (depends on 1) A method of claim 1, wherein the running contact surfaces made in step c) have a beam-like geometry and possess, as viewed in longitudinal direction, a slightly cylindrical shape. ### Claim 5 (depends on 1) A method of claim 1 wherein the running contact surfaces made in step c) extend approximately at a center of the arms. ### Claim 6 (depends on 1) A method of claim 1 wherein step c) is followed by a further step d) in which two aligned receptions are one of punched or bored into the arms in the vicinity of the crossbar that is opposed to the crossbar comprising the cavity, and said receptions serve to receive an axle for the pivoted mounting of the inner lever relative to the outer lever. ### Claim 7 (depends on 1) A method of claim 1, wherein the running contact surface of each arm of the outer lever is intended for a contact with a high-lift cam. ### Claim 8 (depends on 1) A method of claim 1, wherein the finger extends from a center of the crossbar. ### Claim 9 (depends on 8) A method of claim 8, wherein the running contact surfaces made in step c) extend approximately at a center of the arms. ### Claim 10 (depends on 1) A method of claim 1, wherein step c) is followed by a further step d) in which two aligned receptions are one of punched or bored into the arms in a vicinity of the crossbar that is opposed to the crossbar comprising the finger, and said receptions serve to receive an axle for a pivoted mounting of the inner lever relative to the outer lever.