Patent ID: 9669786
Date: 2017-06-06
CPC Classifications: B21D,B23K,B60R

Claim:
1. A reinforcement beam roll formed from a metal sheet, said reinforcement beam comprising: a bumper reinforcement beam for a vehicle that includes adjacent tubes having a metal sheet shaped to include a common center wall and lateral portions of the metal sheet extending from opposing sides of the common center wall that enclose interior volumes of the adjacent tubes to define top and bottom walls of the bumper reinforcement beam that are parallel with the common center wall and front and rear walls of the bumper reinforcement beam that are in coplanar alignment with each other and perpendicular to the common center wall; wherein the adjacent tubes each include a channel rib that is defined by a portion of the respective front wall depressed into the interior volume of the respective adjacent tube longitudinally along the bumper reinforcement beam for stiffening the respective portion of the front wall; wherein seams are defined between the adjacent tubes along the front wall and along the rear wall, and wherein the seams are formed by a bend radius of about 3-9 mm that is roll formed at edge portions of the lateral portions of the metal sheet with a tip of each of the edge portions in abutting and continuous contact with the common center wall; and a weld formed separately in each of the seams on the front and rear walls of the bumper reinforcement beam, wherein the welds are configured to be formed by welders of a weld station that holds a consistent rectangular cross section of the bumper reinforcement beam in place and that holds lateral edges of the metal sheet against the common center wall to substantially close the seams when forming the welds, wherein a rear crevice rib having the bend radius of one of the edge portions is defined by the weld along the seam on the rear wall, and wherein a front crevice rib having the bend radius of the other of the edge portions is defined by the weld along the seam on the front wall between the channel ribs, and wherein the front and rear crevice ribs are generally aligned with the common center wall to improve bending strength and torsional strength of the bumper reinforcement beam.