Hitch ball mount and method of forming the hitch ball mount

A hitch ball mount is shown and described. The hitch ball mount may include a generally tubular body having first and second end portions, the first end portion engageable with a hitch receiver of a towing vehicle, and a drop portion monolithic with the tubular body and formed between the first and second end portions of the tubular member. The hitch ball mount may further include a hitch ball mounting portion monolithic with the drop portion and tubular body, the hitch ball mounting portion formed at the second end portion of the tubular member and extending from the drop portion, where a hitch ball is selectively attachable to the hitch ball mounting portion.

FIELD OF THE INVENTION

The present invention is generally related to a hitch ball mount and, more particularly, to a stamped hitch ball mount and method of forming a hitch ball mount.

BACKGROUND

There are many different kinds of towing systems that are capable of securing a towed vehicle to a towing vehicle. Many of these systems attach in proximity to the rear of the towing vehicle. This results in the towed vehicle being secured to and extending from the rear of such towing vehicle. A common type of rear extending towing system is a trailer hitch receiver that may be attached to the frame of a towing vehicle. The trailer hitch receiver may utilize a cross bar or torsion tube that expands at least a portion of the length of the width of the vehicle and may be secured to the frame of the towing vehicle.

The trailer hitch receiver may include a receiver assembly that is secured to the cross bar, typically by welding such to the cross bar, but it is not limited to such. The receiver assembly may include a receiver tube, which may be of any appropriate shape and size. A hitch ball mount and hitch ball may then be selectively secured to the receiver tube. The hitch ball may be utilized to secure the towed vehicle to the towing vehicle.

It is often desirable to remove the hitch ball from the trailer hitch receiver, particularly when a towed vehicle is not being towed by the towing vehicle. In this situation, it may be desirable to not have the hitch ball extending from the rear of the towing vehicle. Accordingly, it may be desirable to remove the hitch ball from the trailer hitch receiver.

Accordingly, a trailer hitch ball mount is often utilized to selectively attach the hitch ball to the trailer receiver hitch. The trailer hitch ball mount may be capable of being secured to and removed from the trailer hitch receiver. This may result in the trailer hitch ball mount being carried and manipulated by a user when he or she desires to attach or remove the hitch ball. This may allow for the use of multiple hitch balls with different size hitch balls mounted thereon.

During use of the trailer hitch ball mount, however, significant forces are applied. This may result in the trailer hitch ball mount being heavy and difficult for a user to manipulate. For example, some trailer hitch ball mounts are manufactured from a solid forged piece of metal, which is particularly heavy, especially those having a class IV/V rating, or those that may be capable of towing 7000 pound or more. Given that trailer hitch ball mounts are manipulated by users to be secured and removed from the trailer hitch receiver, it is desirable for a hitch ball mount to be of a lighter construction while maintaining its class rating or weight capacity.

Moreover, the traditional hitch ball mount must go through several different steps in manufacturing, which may result in a higher cost to manufacture. For example, the hitch ball mount may be manufactured by welding a pre-formed tongue to a tube or solid bar/rod member. For example, a class I/II/III rated hitch ball mount or a hitch ball mount that may be capable of towing 5000 pounds or less may use a hollow tube welded to a solid thick steel tongue. The additional processing required to weld the components together adds to the time and costs to manufacture the hitch ball mount. It is desirable for the hitch ball mount to be easier and/or more cost effective to manufacture.

SUMMARY

A hitch ball mount is shown and described. The hitch ball mount may include a generally tubular body having first and second end portions, the first end portion engageable with a hitch receiver of a towing vehicle, and a drop portion monolithic with the tubular body and formed between the first and second end portions of the tubular member. The hitch ball mount may further include a hitch ball mounting portion monolithic with the drop portion and tubular body, the hitch ball mounting portion formed at the second end portion of the tubular member and extending from the drop portion, where a hitch ball is selectively attachable to the hitch ball mounting portion.

A hitch ball mount capable of securing a hitch ball to a hitch receiver of a towing vehicle may include a generally tubular body having first and second end portions and a cavity therebetween, the first end portion being engageable with the hitch receiver, and a drop portion monolithic with the tubular body and formed between the first and second end portions of the tubular member. The hitch ball mount may also include a hitch ball mounting portion monolithic with the drop portion and tubular body, the hitch ball mounting formed at the second end portion of the tubular member and extending from the drop portion, where hitch ball mounting portion is generally free of the cavity.

A hitch ball mount capable of securing a hitch ball to a hitch receiver may include a generally tubular body having first and second end portions, the first end portion engageable with a hitch receiver of a towing vehicle, and a drop portion monolithic with the tubular body and formed between the first and second end portions of the tubular member. The hitch ball mount may also include a hitch ball mounting portion formed with and attached to the drop portion free of welding between the hitch ball mounting portion and the drop portion.

A hitch ball mount capable of securing a hitch ball to a hitch receiver may include a monolithic tubular member. The monolithic tubular member may include a first section having a cavity extending a longitudinal length and a second section extending from the first section. The monolithic tubular member may also include a third section extending from the second section, the third section being generally flattened and generally free of the cavity, where the hitch ball is capable of being secured to the third section.

DETAILED DESCRIPTION

A hitch ball mount10may be utilized to operatively secure a towing vehicle12with a towed vehicle in any appropriate manner. The hitch ball mount10may be formed as a monolithic unit or otherwise may be integrally formed. The hitch ball mount10may include a hitch receiver attachment portion14, a drop portion18and a hitch ball mount portion or tongue22, as shown inFIGS. 1-6. The hitch receiver attachment portion14may include a tubular portion26. The tubular portion26may be of any appropriate shape such that it may be capable of operatively engaging a hitch receiver28in any appropriate manner. By way of a non-limiting example, the tubular portion26may be of a generally square, rectangular, oval, circular shape or any combination of such shapes. The tubular portion26may include an aperture, or by way of a non-limiting example a pair of transverse apertures30that are located on at least two sides34of the tubular portion26. The tubular portion26may further include a generally angled end portion35. The angled end portion35may make it easier to load the tubular portion26into mating engagement with the applicable hitch receiver28.

The apertures30may be shaped and sized such that when the hitch receiver attachment portion14selectively engages the trailer hitch receiver28, the trailer hitch receiver may include correspondingly shaped and sized apertures whereby a pin, a lock, or the like38may pass through the apertures30to selectively secure the hitch receiver portion14to the trailer hitch receiver (not shown).

The drop portion18of the hitch ball mount10may extend generally between the hitch receiver attachment portion14and the tongue22. The drop portion18may be of any appropriate distance D as measured vertically from an upper surface37of the receiver portion14to an upper surface40of the tongue22, an example of which is shown inFIG. 2. In some embodiments, the drop portion18may be a zero drop whereby the drop portion18, the upper surface37of the receiver attachment portion14and the tongue22may be generally parallel with each other. The appropriate distance D of the drop portion18may be based upon the distance the tongue22may be desired to extend from the upper surface37of the hitch receiver attachment portion14to account for the use of the hitch ball mount10.

The tongue22may extend from the drop portion18. The tongue22may include a hitch ball aperture44positioned on the upper surface40of the tongue22and may extend through the tongue22. The hitch ball aperture44may be shaped and sized to receive a hitch ball46with nut47that may be selectively engaged with the tongue22in any appropriate manner. Further, the tongue22may include a first recess51generally circumscribing the hitch ball aperture44in an upper surface40of the tongue22. Alternatively or in addition, a second recess51amay be provided around the hitch ball aperture44in a second face44aof the tongue22. The first and second recesses51,51amay have a generally non-circular shape. By way of a non-limiting example, the first and second recesses51,51amay assume an oval, polygonal, square, rectangular, hexagonal, and star shape, or a combination thereof. The first and second recesses51,51amay be of a generally identical shape or may possess different shapes.

In such embodiments, a hitch ball63, an example of which is shown inFIG. 1, having a base65and threaded mounting shank133(such as shown inFIG. 7) may be capable of being selectively secured in the hitch ball aperture44. The base65may be correspondingly sized and shaped to be received and held in at least one of the first and second recesses51,51a. The base65may fit in and generally fill the first or second recess51,51aor may fit in and fill only a portion of the first or second recess51,51a.

A fastener132(such as that shown inFIG. 7) may be provided for engaging the mounting shank133and securing the hitch ball63to the hitch ball mount10, such as by way of a non-limiting example, the fastener132may be a nut132band a lock washer132a. Alternatively, a self-locking nut may be utilized.

The hitch ball63may be easily and conveniently connected to the hitch ball mount10. The mounting shank133of the hitch ball63may be aligned with and pushed through the hitch ball aperture44in the tongue22. As this is done the base65of the hitch ball63may be seated in the recess51, or the second recess51a, as applicable. Once seated, a sidewall74of the recess51may engage a side or sides of the base65so as to effectively prevent the hitch ball63from rotating relative to the hitch ball mount10. The lock washer132amay be placed over the mounting shank133and the nut132bmay then be tightened on that mounting shank133to complete the connection. During the tightening process, the engagement of the base65of the hitch ball63with the sidewall74of the recess51may prevent rotation of the hitch ball63in the hitch ball mount10. This may, therefore, allow connection with a single tool.

The hitch ball mount10may be integrally formed from a single tubular member. By way of a non-limiting example, the hitch ball mount10may be formed from a generally hollow tubular member140, an exemplary embodiment of which is shown inFIG. 14. The hitch ball mount10may be forged, stamped or hydro-formed. In some embodiments, a thinner wall hollow tubular member may be used to create a one piece class I, II, or III (lighter duty) hitch ball mount10and in some embodiments a thicker walled hollow tubular member may be used to create a one-piece class IV or V (or heavy duty) hitch ball mount10.

By way of a non-limiting example, the hitch ball mount10may be formed from a tubular member140such as the generally square cross-section tubular member shown inFIG. 14. The tubular member140, however, is not limited to being a generally square cross-section as shown. The tubular member140may be of any appropriate shape, such as for example, the tubular member140may be generally rectangular, circular, oval, triangular, hexagonal, or any other polygonal shape. The tubular member140may have walls of any appropriate thickness which may depend upon the class of the hitch ball mount (e.g., a higher class or more heavy duty rated hitch ball mount may be made formed from a tubular member having thicker walls than a lower class rated or lighter duty hitch ball mount).

The tubular member140may be of any appropriate length. By way of a non-limiting example, the tubular member140may be approximately 24 inches in length. Although, any appropriate length tubular member140may be used. A longer tubular member may be used when a longer drop configuration D is to be formed. A tube of any length, however, may be used to form the applicable tubular member140. The tube may be cut to length by any appropriate means, such as for example by utilizing a saw that may cut the tube to length. Alternatively, the tubular member140may be formed having the appropriate length and may not need to be cut to length. The tubular member140may be of any appropriate material, such as steel by way of a non-limiting example. Further, the tubular member140may be cut to include the generally angled end portion35as described above. The generally angled end portion35may be formed by utilizing a saw to cut the end thereof.

The tubular member140may be stamped or otherwise formed so as to form the hitch ball mount10. The hitch ball mount10may therefore be a single monolithic unit whereby no additional components may need to be added or otherwise attached. This may result in the hitch receiver portion14, drop portion18and tongue22being a monolithic unit or a single integral piece whereby no other items may need to be attached thereto. The hitch ball mount10may be formed in any appropriate manner. By way of a non-limiting example, the hitch ball mount10may be formed utilizing the tubular member140and stamping, cold forming or hydro-forming.

In some embodiments, a tubular member141may be generally circular in cross-section as shown inFIG. 14. In these embodiments, the receiver attachment portion14may be stamped in the appropriate shape. By way of a non-limiting example, an appropriate portion of the generally circular cross-sectional tubular member141may be stamped to form a generally rectangular or square cross-sectional receiver attachment portion14that may be capable of operatively engaging the hitch receiver28. In these embodiments, the receiver attachment portion14may be stamped on all four sides at once so as to form the generally rectangular or square cross-sectional shape. Further, in these embodiments, the drop portion18and tongue22may be formed through subsequent operation.

In some embodiments, the tubular member140may be hardened by any appropriate manner, which may strengthen the metal used to form the hitch ball mount10. This hardening may occur before forming the hitch ball mount10, after forming the hitch ball mount10, or both before and after forming the hitch ball mount10. By way of a non-limiting example, the tubular member140may be work hardened by any appropriate manner before forming the hitch ball mount10, after forming the hitch ball mount10, or both before and after forming the hitch ball mount10. Further yet, the hitch ball mount10may be annealed to change the material properties such before processing further, after formation or both.

Once the tubular member140is hardened or if it is not to be hardened until after formation or not hardened at all, the tubular member140may be placed in a die145of appropriate shape and size. The shape and size of the die145may depend upon the size and shape of the hitch ball mount10required. In the die145, the tubular member140may be stamped by the appropriate process and machinery. The present teachings are not limited to a specific stamping process; any suitable stamping process may be used.

An exemplary embodiment of the die145is shown inFIGS. 67-68. In these embodiments, the die145may include a bottom die146, shown inFIG. 67and a top die147shown inFIG. 68. The bottom die146may include a pair of upstanding members149that may hold a portion of the tubular member140in the appropriate position when placed in the die145. The top die147may include a pair of upstanding members151, a sloped portion152, and a generally planar portion153. The upstanding members151may hold a portion of the tubular member140in the appropriate position when the top die147engaged the bottom die146, similar to the upstanding members149. Further, the sloped portion152may form the drop portion108and the generally planar portion153may form the tongue22.

In operation of the die145, the tubular member140may be placed in the die145whereby a portion of the tubular member140is held in place by the upstanding members149of the bottom die146. The top die147may then travel toward the bottom die146so that the top die147may engage the tubular member140. In engaging the tubular member140, the upstanding members149of the bottom die146and the upstanding members150of the top die147may generally hold the tubular member140in the appropriate location. The generally planar portion153may engage the tubular member140generally forming the tongue22and the sloped portion152may engage the tubular member140generally forming the drop portion18. The shape and size of the die145may change based upon the desired shape and attributes of the hitch ball mount10required. By way of a non-limiting example, the slope of the sloped portion152of the top die147may be increased or decreased depending upon the required distance D of the drop portion18.

Upon stamping of the tubular member140, the drop portion18may be formed. The stamp may engage the tubular member between its first end and second end portions142,144to form the drop portion18. During this process, however, the first end portion142of the tubular member140may not be stamped such that it forms the hitch receiver portion14. In some embodiments, the apertures30on the hitch receiver portion14may be formed in advance by any suitable process, such as by way of a non-limiting example, stamping, drilling or the like. In some embodiments, the apertures30may be formed after the hitch ball mount10is formed. Further in some embodiments, the apertures30may be formed generally simultaneously with the formation of the drop portion18, the tongue22, or the hitch ball aperture44.

The stamped tubular member140with the drop portion18formed may be placed in another die. This combination may then be stamped, which may form a portion of the tongue22or alternatively, may form the entire tongue22. If only a portion of the tongue22is formed, the stamped combination may be placed in yet another die to complete the formation of the tongue22or may remain in the same die to form the remainder of the tongue22. Alternatively, the stamped tubular member140with the drop portion18may remain in the die used to form such and the combination may be further stamped which may form a portion of the tongue22or alternatively, may form the entire tongue22. If only a portion of the tongue22is formed, the stamped combination may be placed in another die to complete the formation of the tongue22or may remain in the same die to form the remainder of the tongue22.

In some embodiments, the hitch ball aperture44may be formed by placing the hitch ball mount10having had the drop portion18and tongue22formed into another die and stamping the tongue22, which may form the hitch ball mounting aperture44. In other embodiments, the hitch ball aperture44may be formed simultaneously with the stamping of the tongue22. In the alternative, the hitch ball aperture44may be formed by another process, such as by way of a non-limiting example, it may be drilled or the like.

In some embodiments, the tubular member140may be placed in a single die. In this die, the tubular member140may be stamped to form the drop portion18. The combination may be stamped again to form at least a portion of the tongue22, or may form the entire tongue22during the initial stamping process. If the tongue22is not completely formed, the combination may be stamped again to form the remainder of the tongue22. This combination may be stamped to form the hitch ball aperture44, or alternatively, the hitch ball aperture44may be formed with the tongue22during any of the stamping steps.

In some embodiments, the tubular member140may be placed in an appropriate die and the tubular member140be stamped once to form the entire hitch ball mount10, including the drop portion18, the tongue22and the hitch ball aperture44. This may result in the hitch ball mount10being formed in a single step. Alternatively, the hitch ball mount10may be formed in progressive processes, but where the hitch ball mount10remains in a single die.

Further, the hitch ball mount10may be formed through cold forming. The tubular member140may be placed in the appropriate die without any heating of the tubular member140or die. The die may stamp the tubular member140on one side using a dwell press, for example, the stamp presses on the tubular member140within the die and pressure from the press remains applied to the tubular member140forming the hitch ball mount10. The tubular member140may then be removed from the die, turned over (or the die may just be turned over) and the other side of the tubular member140may be pressed using the dwell press process. The dwell press may generally eliminate or at least reduce seams that may otherwise be present. This is especially useful for any seam that may form on the tongue22.

In some embodiments, the hitch ball mount10may be formed from a piece of hollow tube approximately 2″ (50.8 mm) square with a wall thickness of approximately 0.24″ (6 mm), this may be particularly suited for a class III draw bar. This tubular member140may be placed in a die and formed (with or without the application of heat) into the hitch ball mount10with a prearranged amount of drop configuration D. This drop configuration D can be all most negligible to a maximum limited by the tooling.

The hitch ball mount10being formed through stamping may eliminate weld stresses that may otherwise be present with the prior art hitch ball mounts as it may not be necessary to weld any additional components to the hitch ball mount10. Additionally, forming the hitch ball mount10as described above may allow control of stress paths of the hitch ball mount10such that they may flow through the entire hitch ball mount10instead of occurring at the welds as may occur with the prior art hitch ball mounts.

While finishing operations may not be necessary for the hitch ball mount10, certain finishing operations may be desired for purely aesthetical reasons. In some embodiments, an end portion81of the tongue22may undergo a finishing operation, such as by way of a non-limiting example welding the end portion81to make it aesthetically pleasing. In addition or alternatively, the end portion81may be ground down or ground smooth to clean the end portion81or to shape the end portion81to a desired shape. The welding and grinding operations, however, may not be necessary. By way of a non-limiting example, the end portion81of the tongue22may undergo a non-structural weld to generally improve the aesthetic appearance of the end portion81. The end portion81may include a seam82, which may be the result of the stamping process described above. The seam82may have added thereto a protective layer83, such as adding a non-structural weld thereon. This may provide a generally smooth finish to the end portion81and may generally reduce or eliminate the seam82.

Further still, the end portion81may be resisted welded, which may generally eliminate the seam82. After being stamped as described above, the seam82on the end portion81may undergo resistance welding, which may generally eliminate or reduce the seam82. This may further hold together the seam82, which may also generally protect interior components of the hitch ball mount10from the environment. This may generally prevent premature degradation of the materials of the hitch ball mount10.

In some embodiments, the tubular member140A may be bent into a generally lazy S-formation as shown inFIG. 13before stamping. Any appropriate method may be used to bend the tubular member140A, such as by way of a non-limiting example, cold forming or mandrel bending the tubular member104A. While a generally S-shape is shown, the present teachings are not limited to this shape. Any appropriate shape may be used. The generally S-shape may form the hitch receiver portion14, the drop portion18and the tongue22once stamped. By way of a non-limiting example, a top of the bent generally S-shaped tubular member140may form the hitch receiver portion14, a middle portion of the generally S-shaped bent tubular member140may form the drop portion18and a bottom of the generally S-shaped bent tubular member140may form the tongue22. Once the tubular member140A is bent, it may be stamped as indicated above. In some embodiments, while cold-forming and/or prior to cold-forming the tubular member140A may be heated slightly to reduce work hardening. The cold-forming may work harden the tubular member140A.

Some exemplary methods for forming the hitch ball mount10are shown inFIG. 15. As shown in step170, the tubular member140may be provided. The tubular member140may be placed in a die, as shown in step172. Next, the tubular member140may be stamped as shown in step174—the stamping may dwell on the tubular member140to further form the hitch ball mount10. Stamping the tubular member140may form the drop portion18as shown in step176. The tubular member140may then be removed from the die and may be placed in a second die as shown in step178. The tubular member140with drop portion18may then be stamped as shown in step180—the stamping may dwell on the tubular member140to further form the tongue22. This stamping may form the tongue22as shown in step182. The formed hitch ball mount10may be removed from the die as shown in step184.

Further, as shown in box170the tubular member140may be provided. The tubular member140may be cold formed as shown in step186. The tubular member140may be placed in a die, as shown in step188. Next, the tubular member140may be stamped as shown in step190—the stamping may dwell on the tubular member140to further form the hitch ball mount10. Stamping the tubular member140may form the drop portion18as shown in step192. The tubular member140may then be removed from the die and may be placed in a second die as shown in step194. The tubular member140with drop portion18may then be stamped as shown in step196—the stamping may dwell on the tubular member140to further form the tongue22. This stamping may form the tongue22as shown in step198. The formed hitch ball mount10may be removed from the die as shown in step199.

The description of the steps above may be accomplished in any order and certain steps may be skipped or additional steps added thereto. Moreover, the steps may be accomplished completely manually, automatically or by a combination of such. By way of a non-limiting example, a single machine may be used to cut the tube into the appropriate length to form the tubular member140and may possess the appropriate dies and stamping mechanism to form the remainder of the hitch ball mount10.

Additional embodiments of a hitch ball mount according the present teachings are described below. In the descriptions, all of the details and components may not be fully described or shown. Rather, some of the features or components are described and, in some instances, differences with the above-described embodiment may be pointed out. Moreover, it should be appreciated that these additional embodiments may include elements or components utilized in the above-described embodiment although not shown or described. Thus, the descriptions of these additional embodiments are merely exemplary and not all-inclusive nor exclusive. Moreover, it should be appreciated that the features, components, elements and functionalities of the various embodiments may be combined or altered to achieve a desired hitch ball mount without departing from the spirit and scope of the present teachings.

A hitch ball mount100may include a hitch receiver attachment portion104, a drop portion108and a hitch ball mount portion or tongue112as shown inFIGS. 7-12. The hitch receiver attachment portion104may include a tubular portion116. The tubular portion116may be of any appropriate shape such that it may be capable of engaging a trailer hitch receiver. By way of a non-limiting example, the tubular portion116may be generally square, rectangular, oval, circular shape or any combination of such shapes. The tubular portion116may include an aperture, or by way of a non-limiting example a pair of transverse apertures120that are located on at least two sides124of the tubular portion116.

The apertures120may be shaped and sized such that when the hitch receiver attachment portion104selectively engages the trailer hitch receiver, the trailer hitch receiver may include correspondingly shaped and sized apertures. A pin, lock, or the like may pass through the apertures120to selectively secure the hitch receiver portion104to the trailer hitch receiver. Further, any appropriate method and apparatus may be used to selectively secure the hitch receiver portion104to the trailer hitch receiver.

The drop portion108of the hitch ball mount100may extend between the hitch receiver attachment portion104and the tongue112. The drop portion108may be of any appropriate distance D as measured vertically from an upper surface105of the receiver portion104to an upper surface130of the tongue112, an example of which is shown inFIG. 9. In some embodiments, the drop portion108may be a zero drop whereby the drop portion108, the upper surface105of the receiver attachment portion104and the tongue112may be generally parallel with each other. The appropriate distance D of the drop portion108may be based upon the distance the tongue112may be desired to extend from the upper surface105of the hitch receiver attachment portion104to account for the use of the hitch ball mount100.

The tongue112may extend from the drop portion108. The tongue112may include a hitch ball aperture134positioned on the upper surface130of the tongue112and may extend through the tongue112. The hitch ball aperture134may be shaped and sized to receive a hitch ball131with a fastener132that may be selectively engaged with the tongue112in any appropriate manner. By way of a non-limiting example, the hitch ball131may include a base175and a threaded member133extending from the base175. The threaded member133may pass through the hitch ball aperture134and a nut132bmay threadingly engage the threaded member133securing the hitch ball131to the tongue112. In addition, the lock washer132amay be inserted onto the threaded member133.

The hitch ball mount100may be integrally formed from a single tubular member. By way of a non-limiting example, the hitch ball mount100may be formed from a generally hollow tubular member140, an exemplary embodiment of which is shown inFIG. 14. The hitch ball mount100may be forged, stamped or hydro-formed. In some embodiments, a thinner wall hollow tubular member may be used to create a one piece class I, II, or III (lighter duty) hitch ball mount100and in some embodiments a thicker walled hollow tubular member may be used to create a one-piece class IV or V (or heavy duty) hitch ball mount100.

The tubular member140may be stamped or otherwise formed so as to form the hitch ball mount100. The hitch ball mount100may therefore be a single integral piece or monolithic unit whereby no additional components may need to be added or otherwise attached. This may result in the hitch receiver portion104, drop portion108and tongue112being a single integral piece or monolithic unit whereby no other items may need to be attached thereto. The hitch ball mount100may be formed in any appropriate manner. By way of a non-limiting example, the hitch ball mount100may be stamped from the tubular member140or may be hydro-formed.

In some embodiments, the tubular member141may be generally circular in cross-section as shown inFIG. 14. In these embodiments, the receiver attachment portion104may be stamped in the appropriate shape. By way of a non-limiting example, an appropriate portion of the generally circular cross-sectional tubular member141may be stamped to form a generally rectangular or square cross-sectional receiver attachment portion104that may be capable of operatively engaging a hitch receiver. In these embodiments, the receiver attachment portion104may be stamped on all four sides at once so as to form the generally rectangular or square cross-sectional shape. Further, in these embodiments, the drop portion108and tongue112may be formed through subsequent operation.

In some embodiments, the tubular member140may be hardened by any appropriate manner, which may strengthen the metal used to form the hitch ball mount100. This hardening may occur before forming the hitch ball mount100, after forming the hitch ball mount100, or both before and after forming the hitch ball mount100. By way of a non-limiting example, the tubular member140may be work hardened by any appropriate manner before forming the hitch ball mount100, after forming the hitch ball mount100, or both before and after forming the hitch ball mount100. Further yet, the hitch ball mount100may be annealed to change the material properties such before processing further, after formation or both.

Once the tubular member140is hardened or if it is not to be hardened until after formation or not hardened at all, the tubular member140may be placed in a die145of appropriate shape and size. The shape and size of the die145may depend upon the size and shape of the hitch ball mount100required. In the die145, the tubular member140may be stamped by the appropriate process and machinery. The present teachings are not limited to a specific stamping process; any suitable stamping process may be used.

Upon stamping of the tubular member140, the drop portion108may be formed. The stamp may engage the tubular member140between its first end and second end portions142,144to form the drop portion108. During this process, however, the first end portion142of the tubular member140may not be stamped such that it forms the hitch receiver portion104. In some embodiments, the apertures120on the hitch receiver portion104may be formed in advance by any suitable process, such as by way of a non-limiting example, stamping, drilling or the like. In some embodiments, the apertures120may be formed after the hitch ball mount100is formed. Further in some embodiments, the apertures120may be formed generally simultaneously with the formation of the drop portion108, the tongue112, or the hitch ball aperture134.

The stamped tubular member140with the drop portion108formed may be placed in another die. This combination may then be stamped, which may form a portion of the tongue112or alternatively, may form the entire tongue112. If only a portion of the tongue112is formed, the stamped combination may be placed in yet another die to complete the formation of the tongue112or may remain in the same die to form the remainder of the tongue112. Alternatively, the stamped tubular member140with the drop portion108may remain in the die used to form such and the combination may be further stamped which may form a portion of the tongue112or alternatively, may form the entire tongue112. If only a portion of the tongue112is formed, the stamped combination may be placed in another die to complete the formation of the tongue112or may remain in the same die to form the remainder of the tongue112

In some embodiments, the hitch ball aperture134may be formed by placing the hitch ball mount100having had the drop portion108and tongue112formed into another die and stamping the tongue112, which may form the hitch ball mounting aperture134. In some embodiments, the hitch ball aperture134may be formed simultaneously with the stamping of the tongue112. In the alternative, the hitch ball aperture134may be formed by another process, such as by way of a non-limiting example, it may be drilled or the like.

In some embodiments, the tubular member140may be placed in a single die. In this die, the tubular member140may be stamped to form the drop portion108. The combination may be stamped again to form at least a portion of the tongue112, or may form the entire tongue112during the initial stamping process. If the tongue112is not completely formed, the combination may be stamped again to form the remainder of the tongue112. This combination may be stamped to form the hitch ball aperture134, or alternatively, the hitch ball aperture134may be formed with the tongue112during any of the stamping steps.

In some embodiments, the tubular member140may be placed in an appropriate die and the tubular member140be stamped once to form the entire hitch ball mount100, including the drop portion108, the tongue112and the hitch ball aperture134. This may result in the hitch ball mount100being formed in a single step. Alternatively, the hitch ball mount100may be formed in progressive processes, but where the hitch ball mount100remains in a single die.

In some embodiments, the hitch ball mount100may be formed from a piece of hollow tube approximately 2″ (50.8 mm) square with a wall thickness of approximately 0.24″ (6 mm), this may be particularly suited for a class III draw bar. This tubular member140may be placed in a die and formed (with or without the application of heat) into the hitch ball mount100with a prearranged amount of drop configuration D. This drop configuration D can be all most negligible to a maximum limited by the tooling.

The hitch ball mount100being formed through stamping may eliminate weld stresses that may otherwise be present with the prior art hitch ball mounts as it may not be necessary to weld any additional components to the hitch ball mount100. Additionally, forming the hitch ball mount100as described above may allow control of stress paths of the hitch ball mount100such that they may flow through the entire hitch ball mount100instead of occurring at the welds as may occur with the prior art hitch ball mounts.

While finishing operations may not be necessary for hitch ball mount100, certain finishing operations may be desired for purely aesthetical reasons. In some embodiments, an end portion150of the tongue112may undergo a finishing operation, such as by way of a non-limiting example non-structural welding the end portion150to make it aesthetically pleasing. In addition or alternatively, the end portion150may be ground down or ground smooth to clean the end portion150or to shape the end portion150to a desired shape. The welding and grinding operations, however, may not be necessary.

In some embodiments, the tubular member140A may be bent into a generally lazy S-formation as shown inFIG. 13before stamping. Any appropriate method may be used to bend the tubular member140A, such as by way of a non-limiting example, cold forming or mandrel bending the tubular member104A. While a generally S-shape is shown, the present teachings are not limited to this shape. Any appropriate shape may be used. The generally S-shape may form the hitch receiver portion104, the drop portion108and the tongue112once stamped. By way of a non-limiting example, a top of the bent generally S-shaped tubular member140may form the hitch receiver portion104, a middle portion of the generally S-shaped bent tubular member140may form the drop portion108and a bottom of the generally S-shaped bent tubular member140may form the tongue112. Once the tubular member140A is bent, it may be stamped as indicated above. In some embodiments, while cold-forming and/or prior to cold-forming the tubular member140A may be heated slightly to reduce work hardening. The cold-forming may work harden the tubular member140A.

In the alternative, the hitch ball mount100A may be formed solely by bending the tubular member140A and not stamping further. In these embodiments, the tubular member140A may be bent in a generally S-shape to form the hitch receiver portion104A, the drop portion108A and the tongue112A. By way of a non-limiting example, a top of the bent generally S-shaped tubular member140A may form the hitch receiver portion104A, a middle portion of the generally S-shaped bent tubular member140A may form the drop portion108A and a bottom of the generally S-shaped bent tubular member140A may form the tongue112A. In this embodiment, the tongue112A may not have a flattened end portion150A, or in the alternative may have a flattened end portion similar to the embodiment shown inFIGS. 1-6.

A hitch ball mount200shown inFIGS. 16-21may be formed with a larger drop/rise distance D. In order to accommodate taller towing vehicles a larger drop/rise distance D may be necessary for the hitch ball mount200. The hitch ball mount200may be formed as described above. The larger drop/rise distance D, however, may require that the drop portion208be stamped more than once and/or may require a die of a different size. Alternatively, the drop/rise configuration D may be formed in a single stamping step. The remainder of the hitch ball mount200may likewise be formed as describe above.

A hitch ball mount300shown inFIGS. 22-27may be formed with a shape that differs from the hitch ball mount100. Specifically, the hitch receiver portion304may have a more generally square cross-sectional shape and the tongue312may have a different shape. Further, the drop portion308may have a different shape. The hitch ball mount300may be used with different shaped and sized trailer hitch receivers. The remainder of the hitch ball mount300may be formed as describe above. The dies to form such, however, may be of a different shape and sizes.

In some embodiments, a hitch ball mount400may have a tubular portion416that includes walls455that are generally thicker as shown inFIGS. 28-33. The hitch ball mount400having these thicker walls455may be formed as set forth above. The hitch ball mount400having thicker walls455may result in the hitch ball mount400being of a more robust construction so that it may be rated for higher classes of towing. As shown inFIGS. 28-33the walls455being thicker may result in the tongue412being thicker—further resulting in a robust construction. Alternatively, however, the tongue412may not result in being thicker.

In some embodiments, a hitch ball mount500may have a tubular portion516that includes walls555that are generally thicker as shown inFIGS. 34-39. The hitch ball mount500may be formed as set forth above. The hitch ball mount500having thicker walls555may result in the tongue512being wider as indicated by W inFIG. 37. The wider tongue512may be desired depending upon the use of the hitch ball mount500, and may result in the hitch ball mount500being of a more robust construction so that it may be rated for higher classes of towing.

In some embodiments shown inFIGS. 40-46, a hitch ball mount600may include an insert662positioned in the tongue612, which may strengthen the hitch ball mount600. This may result in a more robust construction that may be rated for higher classes of towing, which may permit towing of heavier items. The insert662may be used in addition to or in lieu of having thicker walls of the tubular portion616. In some embodiments, an insert662of any appropriate shape, size and material may be inserted into the tubular member640, such as for example in a second end portion644of the tubular member640. The insert662may be inserted into the tubular member640at any appropriate time during the forming process. By way of a non-limiting example, the insert662may be added to the tubular member640before it may be cold-formed, such as when bent into a generally S shape. In another non-limiting example, the insert662may be inserted into the tubular member640after the tubular member640may be cold-formed. The tubular member640with the insert662inserted therein may be placed into a die and may be stamped to form the tongue612. When stamped, the insert662may be sandwiched within the end portion650of the tongue612. The insert662may be of a material that is harder than the tubular member640. The insert662may act as an inner die that may not generally deform during stamping. This may increase the overall load capacity of the hitch ball mount600.

Alternatively, a portion of the tongue612may be formed by way of non-limiting examples, cold-forming, stamping or a combination of both to form a cavity663shown inFIG. 46. Once the cavity663may be formed the insert662may be inserted within the cavity663. The combination with the insert662in the cavity663may be placed in a die and stamped. This may result in the insert662being sandwiched at the end portion650of the tongue612.

Alternatively, the insert662may be inserted within a die to form the tongue612with insert662. In these embodiments, the tubular member640may be cold-formed, stamped or both. The insert662may be added to the die before or after cold-forming or before or after stamping of the tubular member. Once the insert662is in the die, immediately before stamping the tubular member640, the insert662may be positioned within the tubular member640, such as by way of a non-limiting example, in the second end portion644of the tubular member640and/or the cavity663. The combination of the insert662and tubular member640may be stamped to form the tongue612with insert662.

The insert662may be any appropriate shape or size and are not limited to those shown inFIG. 46. By way of a non-limiting example, the insert662may be a single rectangular box of metal or it could be two or more pieces of metal that may be sandwiched in the tongue612during forming. By way of another non-limiting example, an insert664may be a single rectangular box of metal that includes an aperture668that may correspond with the hitch ball aperture634of the tongue612. In this embodiment, the insert664may be sandwiched in the tongue612whereby forming the hitch ball aperture634may not require stamping, drilling or the like, the insert664as the aperture668is already formed therein. In some embodiments, a plurality of inserts may be used in association with the tongue612such that the inserts may be shaped in such a way to eliminate their ability of working their way free. By way of a non-limiting example, the inserts may have a generally dog bone shape669, as shown inFIG. 46.

Utilizing the inserts662,664,669may permit the tubular member640to have a thinner sidewall655while retaining the required strength. In these embodiments, the inserts662,664,669may be steel or another material. In some non-limiting examples, the inserts662,664,669may be of a metal which may be more malleable, may be of a material that has a hardness that is generally different from the tubular member640, or may be of a material that has generally different strength properties than the tubular member640. The inserts662,664,669may provide the tongue612with added strength, which may make the hitch ball mount600more robust—resulting in it being capable of being used with higher classes of towing or heavier towing. The hitch ball mount600may otherwise be formed as describe above. The hitch ball mount600may include a drop portion608and may include a stepped wall677that may be positioned between the drop portion608and the tongue612. The stepped wall677may be capable of engaging a hitch ball such as the base175of the hitch ball131. In these embodiments, the stepped wall677engaging the base175of the hitch ball131may generally prevent rotation of the hitch ball131during installation thereof on to the hitch ball mount600. More specifically, the stepped wall677may generally prevent the hitch ball131from rotating while the fastener132is being engaged with the threaded member133of the hitch ball131during installation.

In some embodiments, such as those shown inFIGS. 47-52, a hitch ball mount700may include a hitch ball aperture734provided in the tongue712. A recess772may be provided around the hitch ball aperture734in an upper surface730or face of the tongue712. Alternatively or in addition, a second recess (not shown) may be provided around the hitch ball aperture734in a second face781of the tongue712. The recess772may have a generally non-circular shape. By way of a non-limiting example, the recess772may assume an oval, polygonal, square, rectangular, hexagonal, and star shape, or a combination thereof. The second recess may have a generally non-circular shape. The shape of the second recess, by way of a non-limiting example, may assume an oval, polygonal, square, rectangular, hexagonal, and star shape, or a combination thereof. The recess772and the second recess may be of a generally identical shape or may possess different shapes.

In these embodiments, a hitch ball831, an example of which is shown inFIG. 53, having a base875and threaded mounting shank833may be capable of being selectively secured in the hitch ball aperture734. The base875may be correspondingly sized and shaped to be received and held in at least one of the recess772and/or the second recess. Thus, the base875may fit in and generally fill the recess772.

A fastener832may be provided for engaging the shank833and securing the hitch ball831to the hitch ball mount700, such as by way of a non-limiting example, the fastener833may be a nut833and a lock washer837. Alternatively, a self-locking nut may be utilized.

The hitch ball831may be easily and conveniently connected to the hitch ball mount700. The mounting shank833of the hitch ball831may be aligned with and pushed through the hitch ball aperture734in the tongue712. As this is done the base875of the hitch ball831may be seated in the recess772. Once seated, a sidewall774of the recess772may engage a side or sides of the base875so as to effectively prevent the hitch ball831from rotating relative to the hitch ball mount700. The lock washer837may be placed over the mounting shank833and the nut832may then be tightened on that mounting shank833to complete the connection. During the tightening process, the engagement of the base875of the hitch ball831with the sidewall774of the recess772may generally prevent rotation of the hitch ball831in the hitch ball mount700and therefore may allow connection with a single tool.

In some embodiments, the hitch ball mount700may be utilized with the tongue712directed downward or upward, i.e., the drop portion708may either extend downward as is shown inFIG. 49or may extend upward. By way of a non-limiting example, the tongue712may include a recess772and a second recess (not shown) on each of the faces730,781. The base (not shown) of a hitch ball (not shown) may be capable of being received in one recess, in the other recess, or being received in both recesses. In the embodiments in which the base is capable of being received in both recesses, the hitch ball (not shown) may be prevented from rotation in either operating position to allow simple and convenient connection. Moreover, the hitch ball mount700may be capable of selectively attaching to a hitch receiver in a first position whereby the first face730faces upward and the second face781faces downward and a second position whereby the second face781faces upward and the first face730faces downward.

In this embodiment, an insert762may be utilized to help form the recess774. The insert762may be of any appropriate shape and size. By way of a non-limiting example, rods791may be inserted into edges753of the second end portion750of the tongue716. The rods719may be used to better hold the sidewall774of the recess772to form the non-circular recesses. The hitch ball mount700may otherwise be formed as described above.

In some embodiments, such as those shown inFIGS. 53-58, a hitch ball mount800may include a hitch ball aperture834provided in the tongue812. The hitch ball aperture834may be capable of operatively attaching a hitch ball831with a nut832. In some embodiments, a recess872may be provided around the hitch ball aperture834in an upper surface830or face of the tongue812. Alternatively or in addition, a second recess (not shown) may be provided around the hitch ball aperture834in a second face881of the tongue812.

The recess872may have a generally non-circular shape. By way of a non-limiting example, the recess872may assume an oval, polygonal, square, rectangular, hexagonal, and star shape, or a combination thereof. The second recess (not shown) may have a generally non-circular shape. The shape of the second recess, by way of a non-limiting example, may assume an oval, polygonal, square, rectangular, hexagonal, and star shape, or a combination thereof. The recess872and the second recess may be generally identical or may possess different shapes. This may allow the hitch ball mount800to be selectively attachable to a hitch receiver in a first and second position. The recess872may engage a base875of the hitch ball831to prevent rotation of the hitch ball831during installation thereof onto the tongue812. More specifically, the base875may engage the recess872to prevent rotation of the hitch ball831while the nut832may be screwed onto the hitch ball831.

In some embodiments, a hitch ball mount900may be formed from a generally planar plate as shown inFIGS. 59-61. In these embodiments, the generally planar plate may be stamped to form the hitch ball mount900. Specifically, the generally planar plate may be placed in a die of appropriate shape and size. The shape and size of the die may depend upon the size and shape of the hitch ball mount900required. In the die, generally planar plate may be stamped by the appropriate process and machinery. The present teachings are not limited to a specific stamping process; any suitable stamping process may be used, such as by way of a non-limiting example hydro-forming.

Upon stamping of the generally planar plate, the hitch receiver portion904, the drop portion908, and tongue912may all be formed. Apertures920on the hitch receiver portion904may be formed in advance by any suitable process, such as by way of a non-limiting example, stamping, drilling or the like. The apertures920may be formed after the hitch ball mount900is formed. Further, the apertures920may be formed generally simultaneously with the formation of the hitch receiver portion904, the drop portion908, the tongue912, and/or the hitch ball aperture934.

The hitch receiver portion904, the drop portion908, and tongue912may be formed generally simultaneously or may be formed in progressive steps. In addition, a hitch ball aperture934may be formed by stamping the tongue912generally simultaneously with the remainder of the hitch ball mount or may by formed as part of a progressive step. In addition, the hitch ball aperture934may be formed by another process, such as by way of a non-limiting example, it may be drilled or the like.

The drop portion908may be formed with any appropriately sized drop/rise configuration926, which may also include a zero drop whereby the hitch receiver portion904, the drop portion908and the tongue912may be generally planar. The drop/rise configuration926may be controlled by the size of the generally planar plate used, how much the drop portion908is displaced when stamped, or by any combination of such.

In some embodiments, a hitch ball mount1000may be formed from a generally planar plate as shown inFIGS. 62-64. In these embodiments, the generally planar plate may be stamped to form the hitch ball mount1000. Specifically, the generally planar plate may be placed in a die of appropriate shape and size. The shape and size of the die may depend upon the size and shape of the hitch ball mount1000required. In the die, generally planar plate may be stamped by the appropriate process and machinery. The present teachings are not limited to a specific stamping process; any suitable stamping process may be used, such as by way of a non-limiting example hydro-forming.

Upon stamping of the generally planar plate, the hitch receiver portion1004, the drop portion1008, and tongue1012may all be formed. Apertures1020on the hitch receiver portion1004may be formed in advance by any suitable process, such as by way of a non-limiting example, stamping, drilling or the like. The apertures1020may be formed after the hitch ball mount1000is formed. Further, the apertures1020may be formed generally simultaneously with the formation of the hitch receiver portion1004, the drop portion1008, the tongue1012, and/or the hitch ball aperture1034.

The hitch receiver portion1004, the drop portion1008, and tongue1012may be formed generally simultaneously or may be formed in progressive steps. In addition, a hitch ball aperture1034may be formed by stamping the tongue1012generally simultaneously with the remainder of the hitch ball mount or may by formed as part of a progressive step. In addition, the hitch ball aperture1034may be formed by another process, such as by way of a non-limiting example, it may be drilled or the like.

The drop portion1008may be formed with any appropriately sized drop/rise configuration1026. The drop/rise configuration1026may be controlled by the size of the generally planar plate used, how much the drop portion1008is displaced when stamped, or by any combination of such.

In embodiments shown inFIG. 65, a hitch ball mount1100may include a hitch receiver portion1104, a drop portion1108, and a tongue1112; all of which may be formed by stamping as described above. The tongue1112may include first and second end portions1187,1189respectively. These end portions1187,1189may include generally bent portions1194,1196that may likewise be formed by stamping. The bent portions1194,1196may be formed simultaneously with the stamping that may form the hitch receiver portion1104, drop portion1108, and/or tongue1112. Alternatively, the bent portions1194,1196may be formed in a progressive step such as by way of a non-limiting example stamping the tongue1112. As shown inFIG. 65, the tongue1112may include a hitch ball aperture1134, which may be formed as described above.

In embodiments shown inFIG. 66, a hitch ball mount1200may include a hitch receiver portion1204, a drop portion1208, and a tongue1212; all of which may be formed by stamping as described above. The tongue1212may include first and second end portions1287,1289respectively. These end portions1287,1289may include generally bent portions1294,1296that may likewise be formed by stamping. The bent portions1294,1296may be formed simultaneously with the stamping that may form the hitch receiver portion1204, drop portion1208, and/or tongue1212. Alternatively, the bent portions1294,1296may be formed in a progressive step such as by way of a non-limiting example stamping the tongue1212. As shown inFIG. 66, the tongue1212may include a hitch ball aperture1234, which may be formed as described above. In these embodiments, inserts1291may be used and may be sandwiched in the tongue1212as described above. The shape and size of the inserts1291may be such that generally raised longitudinal members1297may be formed on an upper surface1230of the tongue1212.

A hitch ball mount1300may be formed from generally hollow tubular member1340as shown inFIGS. 69-71. In these embodiments, a portion1341of the generally hollow tubular member1340may be removed by any appropriate manner, such as for example cutting, machining a groove or otherwise generally removing the portion1341of the tubular member1340. Once the portion1341is removed from the generally hollow tubular member1340, the generally hollow tubular member1340may be stamped to form a hitch ball mount1300. Removing the portion1341may generally remove or eliminate the stresses in a side wall1365of the hitch ball mount1300when stamped.

The portion1341removed from the tubular member1340may be of any appropriate shape and size. By way of a non-limiting example, the portion1341may be of any appropriate width. Further, the portion1341removed from the tubular member1340may be generally linear, s-shape, arched, or the like. By way of a non-limiting example, the portion1341may be a hole, a slit, a slotted hole, or a slot of any profile. The portion1341removed from the tubular member1340may be in any portion of the sidewall1365; it is not limited to the general center of the tubular member1340as shown inFIG. 70. The portion1341removed from the tubular member1340may be formed in any appropriate manner. By way of a non-limited example, the removed portion1341may be cut with a saw, mill, plasma cutter, water jet, laser, or the like.

Upon stamping of the tubular member1340with the removed portion1341, the hitch receiver portion1304, the drop portion1308, and tongue1312may all be formed. As shown inFIG. 71, the tubular member1340may be stamped so that the location of the removed portion1341may form the drop portion1308and the tongue1312. The hitch receiver portion1304, the drop portion1308, and tongue1312may be formed generally simultaneously or may be formed in progressive steps. In addition, a hitch ball aperture1334may be formed by stamping the tongue1312generally simultaneously with the remainder of the hitch ball mount or may by formed as part of a progressive step. In addition, the hitch ball aperture1334may be formed by another process, such as by way of a non-limiting example, it may be drilled or the like.

In some embodiments, a hitch ball mount1400may be formed from generally hollow tubular member1440as shown inFIGS. 72 and 73. In these embodiments, a portion1441of the generally hollow tubular member1440may be removed by any appropriate manner, such as for example cutting, machining a groove or otherwise generally removing the portion1441of the tubular member1440. Once the portion1441is removed from the generally hollow tubular member1440, the generally hollow tubular member1440may be stamped to form a hitch ball mount1400. Removing the portion1441may generally remove or eliminate the stresses in a side wall1465of the hitch ball mount1400when stamped.

The portion1441removed from the tubular member1440may be of any appropriate shape and size. By way of a non-limiting example, the portion1441may be of any appropriate width. Further, the portion1441removed from the tubular member1440may be generally linear, s-shape, arched, or the like. By way of a non-limiting example, the portion1441may be a hole, a slit, a slotted hole, or a slot of any profile. The portion1441removed from the tubular member1440may be in any portion of the sidewall1465; it is not limited to the general center of the tubular member1440as shown inFIG. 72. The portion1441removed from the tubular member1440may be formed in any appropriate manner. By way of a non-limited example, the removed portion1441may be cut with a saw, mill, plasma cutter, water jet, laser, or the like. The removed portion1441may be positioned at any appropriate position along with tubular member1440. It may be positioned in proximity to an end portion thereof, but may not extend all the way to the end as shown.

Upon stamping of the tubular member1440with the removed portion1441, the hitch receiver portion1404, the drop portion1408, and tongue1412may all be formed. As shown inFIG. 74, the tubular member1440may be stamped so that the location of the removed portion1441may form the drop portion1408and a portion of the tongue1412, but may not extend to an end of the tongue1412. The hitch receiver portion1404, the drop portion1408, and tongue1412may be formed generally simultaneously or may be formed in progressive steps. In addition, a hitch ball aperture1434may be formed by stamping the tongue1412generally simultaneously with the remainder of the hitch ball mount or may be formed as part of a progressive step. In other embodiments, the hitch ball aperture1434may be formed by another process, such as by way of a non-limiting example, it may be drilled or the like.

In some embodiments, a removed portion1541may include a generally backward S-shape with a hole formed in a generally tubular member1540as shown inFIG. 74. The removed portion1541may be of any appropriate shape and size and the present teachings are not limited to such.

A hitch ball mount1600may be formed as a monolithic unit or otherwise may be integrally formed. The hitch ball mount1600may include a hitch receiver attachment portion1614, a drop portion1618and a hitch ball mount portion or tongue1622, as shown inFIGS. 75-76. The hitch receiver attachment portion1614may include a tubular portion1626. The tubular portion1626may be of any appropriate shape such that it may be capable of operatively engaging a hitch receiver in any appropriate manner. By way of a non-limiting example, the tubular portion1626may be of a generally rectangular shape. The tubular portion1626may include a pair of transverse apertures1630located on at least two sides1634of the tubular portion1626. The tubular portion1626may further include a generally angled end portion1635. The angled end portion1635may make it easier to load the tubular portion1626into mating engagement with the applicable hitch receiver.

The drop portion1618of the hitch ball mount1600may extend generally between the hitch receiver attachment portion1614and the tongue1622. The drop portion1618may be of any appropriate distance. In some embodiments, the drop portion1618may be a zero drop. The appropriate distance of the drop portion1618may be based upon the distance the tongue1622may be desired to extend from the hitch receiver attachment portion1614to account for the use of the hitch ball mount1600.

The tongue1622may extend from the drop portion1618. The tongue1622may include a hitch ball aperture1644positioned on the upper surface1640of the tongue1622and may extend through the tongue1622. The hitch ball aperture1644may be shaped and sized to receive a hitch ball in any appropriate manner.

A hitch ball mount1700may be formed as a monolithic unit or otherwise may be integrally formed. The hitch ball mount1700may include a hitch receiver attachment portion1714, a drop portion1718and a hitch ball mount portion or tongue1722, as shown inFIGS. 77-78. The hitch receiver attachment portion1714may include a tubular portion1726. The tubular portion1726may be of any appropriate shape such that it may be capable of operatively engaging a hitch receiver in any appropriate manner. By way of a non-limiting example, the tubular portion1726may be of a generally rectangular shape. The tubular portion1726may include a pair of transverse apertures1730located on at least two sides1734of the tubular portion1726. The tubular portion1726may further include a generally angled end portion1735. The angled end portion1735may make it easier to load the tubular portion1726into mating engagement with the applicable hitch receiver.

The drop portion1718of the hitch ball mount1700may extend generally between the hitch receiver attachment portion1714and the tongue1722. The drop portion1718may be of any appropriate distance. In some embodiments, the drop portion1718may be a zero drop. The appropriate distance of the drop portion1718may be based upon the distance the tongue1722may be desired to extend from the hitch receiver attachment portion1714to account for the use of the hitch ball mount1700.

The tongue1722may extend from the drop portion1718. The tongue1722may include a hitch ball aperture1744positioned on the upper surface1740of the tongue1722and may extend through the tongue1722. The hitch ball aperture1744may be shaped and sized to receive a hitch ball in any appropriate manner.

While the present teachings disclose stamping as a method of forming the hitch ball mount, the present teachings are not limited to such. Any appropriate process may be used to form the hitch ball mount. By way of a non-limiting example, the hitch ball mount may be formed by hydro-forming, particularly, the hitch ball mounts1100,1200. In these embodiments, a generally planar plate may be placed in a die. A bladder may begin to engage the generally planar plate and may stamp the generally planar plate forming the hitch ball mounts1100,1200. Hydraulic fluid may be used with the bladder to form the appropriate the hitch ball mounts1100,1200. Hydro-forming may be used to generally avoid contact points and to spread out the stress over substantially all of the hitch ball mounts1100,1200. The present teachings, however, are not limited to a specific stamping process. Any kind of appropriate process may used without departing from these teachings.

Although the embodiments of the present invention have been illustrated in the accompanying drawings and described in the foregoing detailed description, it is to be understood that the present invention is not to be limited to just the embodiments disclosed, but that the invention described herein is capable of numerous rearrangements, modifications and substitutions without departing from the scope of the claims hereafter. The claims as follows are intended to include all modifications and alterations insofar as they come within the scope of the claims or the equivalent thereof.