# Patent

## Title
Methods for making a vehicular subassembly with a notched flange to reduce strain in bending

## Abstract

A method of making a vehicular subassembly includes a step for providing a roof header comprising a hollow member having a long axis, a short axis, and an outer surface that includes a flange. The method also includes a step of stretch bending the member such that the outer surface is substantially in tension and curved in the short axis direction. The method further includes a step of cutting a plurality of notched elements into the flange to reduce strain from the stretch bending step. In some aspects, the step of cutting can be conducted before the stretch bending to reduce strain in the header associated with the subsequent stretch bending.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional application under 35 U.S.C. § 121 of U.S. patent application Ser. No. 14/076,746, filed on Nov. 11, 2013, entitled “EXTRUDED BODY COMPONENT WITH NOTCHED FLANGE TO REDUCE STRAIN IN BENDING,” issued as U.S. Pat. No. 9,027,989, which is a continuation-in-part application under 35 U.S.C. § 120 of U.S. patent application Ser. No. 14/062,510, filed on Oct. 24, 2013, entitled “HEADER BEAM OF A VEHICLE FRAME AND METHOD OF FORMING THE SAME,” issued as U.S. Pat. No. 9,199,293, and is also a continuation-in-part application under 35 U.S.C. § 120 of U.S. patent application Ser. No. 14/062,568, filed on Oct. 24, 2013, issued as U.S. Pat. No. 8,998,307, entitled “HEADER BEAM OF A VEHICLE FRAME AND METHOD OF FORMING THE SAME.” The aforementioned related applications are hereby incorporated by reference.


FIELD OF THE INVENTION
The present invention generally relates to vehicular subassemblies and body components suitable for bending processes, particularly hollow roof header members amenable to stretch bending manufacturing processes.
BACKGROUND OF THE INVENTION
Bending, stamping, stretch bending and other metal forming processes are used in the vehicle industry to shape precursor components into final or near-final component shapes. Often, these processes produce significant strain in precursor components fabricated from metals and metal alloys, e.g., hollow body members. As such, the precursor components should be designed to accommodate the strain associated with final manufacturing processes, and the engineering considerations associated with the particular final component in service. There is therefore a need to develop design features and processes in consideration of these strain-inducing manufacturing technologies, particularly as employed for hollow vehicle members.
SUMMARY OF THE INVENTION
According to one aspect of the present invention, a method of making a vehicular subassembly is provided. The method includes a step for providing a roof header comprising a hollow member having a long axis, a short axis, and an outer surface that includes a flange. The method also includes a step of stretch bending the member such that the outer surface is substantially in tension and curved in the short axis direction. The method further includes a step of cutting a plurality of notched elements into the flange to reduce strain from the stretch bending step.
According to another aspect of the present invention, a method of making a vehicular subassembly is provided. The method includes a step for forming a roof header comprising a hollow member having a long axis, a short axis, and an outer surface that includes a flange. The method also includes a step of cutting a plurality of notched elements into the flange to reduce strain from a subsequent stretch bending. The method further includes a step of stretch bending the member such that the outer surface is substantially in tension and curved in the short axis direction.
According to a further aspect of the present invention, a method of making a roof header is provided. The method includes: extruding a beam; cutting the beam into beam segments; and forming a segment into a roof header comprising a long axis, a short axis, and an outer surface that includes a front flange. The method also includes a step of stretch bending the header such that the outer surface is substantially in tension and curved in the short axis direction. The method further includes a step of cutting a plurality of notched elements into the flange to reduce strain from stretch bending.
These and other aspects, objects, and features of the present invention will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings.



BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a perspective view of a vehicle containing a roof header assembly with notched elements configured to reduce bending strain according to one embodiment;
FIG. 2 is a perspective view of the roof header assembly with notched elements depicted in FIG. 1;
FIG. 2A is a cut-away, enlarged view of a roof header assembly with notched elements beneath a roof element as depicted in FIG. 1;
FIG. 3A is a cross-sectional view of the roof header assembly with notched elements depicted in FIG. 1;
FIG. 3B is a cross-sectional view of a roof header assembly with notched elements and a substantially oval-shaped cross-section according to another embodiment; and
FIG. 4 is a flowchart showing a method of forming a roof header assembly according to a further embodiment.



DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to a detailed design; some schematics may be exaggerated or minimized to show function overview. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one with ordinary skill in the art to variously employ the present invention.
For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the vehicle and components illustrated in FIG. 1. However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.
Referring to FIG. 1, reference numeral 300 generally designates a vehicular subassembly (e.g., a sun roof header element, A-pillar, B-pillar, C-pillar, roof header, etc.) and reference numeral 100 generally designates a roof header, as an exemplary vehicular subassembly, for the roof element 50 of a vehicle 10. The roof header 100 typically comprises a substantially hollow member (e.g., hollow member 100b as depicted in FIG. 2), configured to support a front portion of roof element 50. The roof header 100 may be fabricated from any materials capable of being manufactured through bending, flexing and stretch bending processes. Preferably, roof header 100 is fabricated from an aluminum alloy, such as a 6000 series extruded aluminum alloy. For example, header 100 can be fabricated from a 6082-T4 extruded alloy, tempered to a T6 condition after fabrication.
As shown in FIGS. 2, 2A, the roof header 100 (as an exemplary vehicular subassembly 300) includes a hollow member 100b, a long axis 80, a short axis 90 and an outer surface 120 substantially parallel to the long axis 80. The outer surface 120 may include notched elements 110 (see also FIG. 1), each configured to reduce strain associated with bending forces 95 applied to the header 100 in the direction of the short axis 90. It should be understood that additional bending forces (not shown) may also be applied to header 100 in other directions. For example, additional bending forces could be applied to the header 100 in the thickness direction, resulting in curvature on the upper-most surface 122 of the header 100. Such curvature could be employed to accommodate a like-curved roof element 50 above the upper-most surface 122.
The outer surface 120 may also include a flange 136, configured with the notched elements 110 as shown in FIGS. 2, 2A. Flange 136 may be a tongue-like feature that emanates from the body of the roof header 100 in the direction of the short axis 90. The flange 136 can serve to provide additional support for a frontal edge of roof element 50 (see FIGS. 1, 2A), particularly for designs of vehicle 10 having a roof element 50 with a feature that extends into the windshield region.
The notched elements 110 depicted in FIGS. 2, 2A may have a variety of shapes, provided that the selected shape reduces strain in the roof header 100 when the header 100 is subjected to a process that applies a bending force 95 generally in the direction of the short axis 90. The notched elements 110 have the effect of reducing the width of the header 100 in the direction of the short axis 90 at the location of the notches. Bending strains associated with bending forces 95, particularly on the outer surface 120 of the header 100, decrease as a function of decreasing width of the header 100.
As also shown in FIGS. 2, 2A, the notched elements 110 can be arranged symmetrically on either side of the centerline 60 along the long axis 80 of the roof header 100. In particular, two notched elements 110, spaced equally apart, are located on one side of the centerline 60 and two notched elements 110 are located on the other side of the centerline 60. Other configurations are possible with one to any number of notched elements 110 on either side of the centerline 60. The number, location and shape of notched elements 110 can be limited by the length of long axis 80 and the particular need for strain relief associated with the contemplated stretch bending, flexing or other part fabrication processes. Preferably, the notched elements 110 have smooth surfaces and large radii to reduce the likelihood of any localized stress concentration-related fatigue effects.
Referring now to FIG. 3A, a cross-section 102 of the roof header 100 is depicted that demonstrates that the header 100 is substantially hollow. In the particular aspect depicted in FIG. 3A, the cross-section 102 is substantially quadrilateral or, more preferably, substantially rectangular in shape. Two ribs 106 are configured within the hollow cavity of header 100 and support the upper-most surface 122 and lower-most surface 124 of the header 100. The presence of ribs 106 as shown in FIG. 3A, creates three primary cavities within header 100. Preferably, the ribs 106 are angled as shown to provide additional support for the upper-most surface 122 during stretch bending, flexing or other part fabrication processes used to form the header 100. The angled nature of ribs 106 also serves to maximize available area on the central portion 124 that can be used for the attachment of other components in vehicle 10 (see FIG. 1) to the header 100 (e.g., A-pillars, B-pillars, etc.). Again referring to FIG. 3A, one or more ribs 106 can be configured within header 100 in consideration of the final design shape of the header 100, support needed for roof element 50 and support needed for the header 100 during part forming processes, and other engineering considerations.
In FIG. 3B, the cross-section 102a of a roof header 100a is depicted with a substantially oval shape. Roof header 100a is similar to roof header 100, differing only in its cross-sectional shape. The oval-shaped cross-section 102a possesses an outer surface 120 containing notched elements 110 (not shown). Even more preferably, a flange 136 will be configured to emanate from the outer surface 120 in a tongue-like shape, with the flange 136 containing the notched elements 110.
The roof header 100 depicted in FIGS. 1-3B is exemplary of other types of vehicular subassemblies 300 (see FIGS. 1-2) that can be fabricated according to other aspects of the present invention. As such, other vehicular subassemblies 300 (see FIGS. 1-2) can be employed based on the foregoing teachings in which the subassemblies have a substantially hollow member (e.g., the hollow member 100b is configured as a roof header 100, as depicted in FIG. 2), a long axis (e.g., long axis 80), a short axis (e.g., short axis 90), and an outer surface substantially parallel to the long axis (e.g., outer surface 120). These other vehicular subassemblies are further defined such that their outer surface features (e.g., outer surface 120) include a plurality of notched elements (e.g., notched elements 110) configured to reduce strain associated with bending the assembly in the direction of the short axis (e.g., short axis 90). For example, these subassemblies can include, but are not limited to, vehicular bumper elements, sun roof header elements, A-pillars, B-pillars, C-pillars, etc.). In particular, these subassemblies may be stretch formed, flexed, stamped, pressed, or otherwise machined in a fashion that can provide significant strain on some of their features. Given that these subassemblies experience significant strain associated with their manufacturing into a final part form, notched elements (e.g., notched elements 110) integrated into their surfaces, particularly surfaces that will be placed in tension from such part-forming processes, provide significant advantages in terms of strain reduction.
Referring now to FIG. 4, a flowchart illustrates one embodiment of a method of forming 200 for a roof header 100, or vehicular subassembly 300, including steps 210 through 232. At step 210, a continuous beam 212 is extruded from an extrusion die 214. The continuous beam 212 is cut at a cutting station 216 to form a beam segment 218 with ends generally perpendicular to the long axis 80 of the beam segment 218. The beam segments 218 are then accumulated in stacks for transportation. The continuous beam 212 and, therefore, the roof header 100 of the illustrated embodiment is extruded primarily from aluminum or an aluminum alloy, although it is understood that additional and alternative materials may be used to form the roof header 100. It is also contemplated that the roof header 100, or portions thereof, may be formed from alternative metals and, alternatively, may be roll formed, hydroformed, or alternatively joined, such as by laser or arc welding.
The beam segments 218, as shown at step 220 of FIG. 4, are unstacked, measured, and centered on a conveyor, each becoming a precursor to the final roof header 100 (e.g., typically comprising a hollow member 100b as shown in FIG. 2) component or vehicular subassembly 300 (see steps 230 and 232 depicted in FIG. 4) having front and rear flanges 136 and 158, respectively (see steps 221 and 232 depicted in FIG. 4). The conveyor feeds the beam segments 218 to a trimming station, depicted in step 221, where the rear flange 158 of the roof header 100 that extends continuously along the long axis 80 of the beam segment 218 is trimmed. More specifically, the rear flange 158 is cut, stamped, or otherwise machined to form an elongated cutout 159 that defines rearward projections of the rear flange 158 proximate the end portions 132 (see step 222) of the beam segment 218 and, ultimately, header 100.
As also shown in FIG. 4, at step 222, the end portions 132 of the beam segment 218 are clamped with a bending device 224 that securely attaches to the end portions 132 of the beam segment 218. The bending device 224 in the illustrated embodiment has two clamping units 226 that clamp the end portions 132 equally to center the beam segment 218 between the two clamping units 226.
At step 228, the bending device 224 moves the clamping units 226 in generally opposite, rotational directions to generate bending forces 95 (e.g., rotational forces) that stretch bend the central portion 124 of the beam segment 218 to produce curvature 128 in the surfaces, including the outer surface 120, of the header 100. For example, the beam segment 218 (i.e., the precursor for header 100) can be subjected to a stretch bending procedure in a direction substantially oriented along its short axis 90 (see step 221).
In some embodiments, the bending device 224 can be configured to stretch bend the beam segment 218 in three dimensions, such that the rear flange 158 undergoes some compression, and the central portion 124 and the outer surface 120 are placed in tension from the process. However, the elongated cutout 159 in the rear flange 158 significantly reduces compression in the rear flange 158 to prevent buckling or undesirable curvature during the stretch bending process. It is understood that in additional embodiments, the bending device 224 may have one clamping unit 226 that moves relative to a stationary clamping unit 226 to stretch and bend the beam segment 218 to the desired curvature in the exterior surfaces of header 100. The clamping units 226 are released from the beam segment 218 in step 230, and the end portions 132 of the beam segment 218 remain generally straight, as previously described.
Still referring to FIG. 4, at step 232, a press with a cutting die 233 strikes the front flange 136 of the beam segment 218 with a pattern that provides generally uniform front edges 166 of the front flanges 136 across production of multiple beam segments 218. More specifically, the front flange 136 is struck to form the front edge 166 that is parallel to the curvature 128 proximate the end portions 132 of the beam for engaging the windshield (not shown).
Still referring to FIG. 4, the cutting die 233 also forms the series of notched elements 110 on the outer surface 120 comprising the front flange 136 to reduce tension (and relieve strain) in the front flange 136 caused by the stretch bending process and to provide points of connection for roof element 50 (not shown). As noted earlier, the notched elements 110 interface with the roof element 50 (see FIG. 1) to also provide an area to relieve fluid buildup between the front flange 136 and the roof element 50, such as during the painting process of the vehicle 10 (see FIGS. 1 and 2A) or from weather-related precipitation. Further, cutting the notched elements 110 in the front flange 136 also provides a weight savings in the header 100, while not detrimentally affecting the additional load bearing capacity offered by the front flange 136 of the header 100. It should be understood that other procedures besides die cutting may be employed to form the notched elements 110, including stamping, laser cutting, water cutting and other machining processes as readily understood by those with ordinary skill in the art.
In another alternative embodiment, the aspects of step 232 shown in FIG. 4 related to cutting notched elements 110 from front flange 136 are conducted in step 221. In this alternative procedure according to method 200, step 232 is deleted. Otherwise, the method 200 for forming the roof header 100 proceeds in the same manner. When the notched elements 110 are cut from the front flange 136 in step 221, the subsequent stretch bending process of step 228 is conducted with greater ease. The removal of material associated with notched elements 110 tends to reduce the overall thickness of beam segment 218, thus reducing the overall strain associated with the stretch bending process of step 228.
The roof header 100 and the other vehicular subassemblies described in the foregoing possess several advantageous features. Notably, the notched elements 110 of the roof header 100 and the foregoing vehicular subassemblies significantly reduce strain associated with manufacturing processes for the header 100 itself. The notched elements 110 also provide some weight savings, which can translate into some fuel efficiency improvements for the vehicle 10. Still further, in some embodiments, the notched elements 110 can be carefully configured beneath roof element 50 to facilitate water drainage from rain and other precipitation. In addition, the notched elements 110 can provide a means for paint drainage during and after e-coating and other painting processes used to deploy paint and other coating features on the roof element 50, header 100 and other vehicular components in proximity to the roof element 50 and header 100.
It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present invention. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.
It is to be understood that variations and modifications can be made on the aforementioned structure without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.

## Claims

1. A method of making a vehicular subassembly, comprising:
providing a roof header comprising a hollow member having a long axis, a short axis, and an outer surface that includes a flange;
stretch bending the member such that the outer surface is in tension and curved in the short axis direction; and
cutting a plurality of notched elements into the flange after the stretch bending step to reduce strain.

2. The method of claim 1, wherein the hollow member further comprises a quadrilateral cross-section.

3. The method of claim 1, wherein the hollow member further comprises an oval-shaped cross-section.

4. The method of claim 1, wherein the step for cutting the plurality of notched elements into the flange comprises a process selected from the group consisting of stamping, die cutting, laser cutting, water cutting, and machining processes.

5. The method of claim 1, wherein the step for providing the roof header comprises an extrusion process.

6. The method of claim 1, wherein the step for providing the roof header comprises extruding the roof header primarily from aluminum or an aluminum alloy.

7. A method of making a roof header, comprising:
extruding a beam;
cutting the beam into beam segments;
forming a segment into a roof header comprising a long axis, a short axis, and an outer surface that includes a front flange;
stretch bending the header such that the outer surface is in tension and curved in the short axis direction; and
cutting notched elements into the flange after the stretch bending step to reduce strain.

8. The method of claim 7, wherein the roof header further comprises a quadrilateral cross-section.

9. The method of claim 7, wherein the roof header further comprises an oval-shaped cross-section.

10. The method of claim 7, wherein the step for cutting the plurality of notched elements into the flange comprises a process selected from the group consisting of stamping, die cutting, laser cutting, water cutting, and machining processes.

11. The method of claim 7, wherein the step for extruding a beam comprises extruding the beam primarily from aluminum or an aluminum alloy.

12. The method of claim 7, wherein the roof header further comprises a rear flange, and the step for stretch bending the header is further conducted such that the rear flange is in compression and curved in the short axis direction.