Patent ID: 8716624

Claim:
A method of roll forming a multi-tubular reinforcement beam for a vehicle, comprising: providing a sheet that includes a generally planar body extending laterally between a first edge and a second edge of the sheet; providing a roll former that includes at least a first set of rollers and a second set of rollers that are configured to sequentially receive the sheet; bending the sheet with the first set of rollers to form a center wall section in generally perpendicular orientation relative to first and second lateral portions of the sheet that extend in opposing directions from respective first and second ends of the center wall section; bending the first and second edges of the respective first and second lateral portions of the sheet with the first set of rollers to form a radius on each of the first and second edges; bending the first and second lateral portions of the sheet simultaneously in the same rotational direction with the second set of rollers to engage the first edge with the second end of the center wall and the second edge with the first end of the center wall to define a first tube and an adjacent second tube, wherein the radii of the first and second edges each contact the center wall section to define a valley for receiving a weld; and welding in the valley to attach the first and second edges respectively with the second and first ends of the center wall.