U.S. patent application number 11/208409 was filed with the patent office on 2007-02-22 for gooseneck beam.
Invention is credited to Joseph Binkowski, Christian Holl, Sivanathan Prasoody.
Application Number | 20070039282 11/208409 |
Document ID | / |
Family ID | 37766213 |
Filed Date | 2007-02-22 |
United States Patent
Application |
20070039282 |
Kind Code |
A1 |
Holl; Christian ; et
al. |
February 22, 2007 |
Gooseneck beam
Abstract
A beam having a gooseneck shape with two gooseneck portions. The
beam may have a variety of cross sectional configurations. One such
configuration has an upper front wall, a lower front wall, and an
offset wall there between. The offset wall may be recessed, or
offset away from the body of the beam. Also disclosed is a method
of manufacturing the gooseneck beam by positioning a length of a
material on a flat surface of a two-cam rotating member; gripping
said material with said two-cam rotating member; restraining said
length; rotating said two-cam rotating member to form a first and
second; and pressing a portion of said material.
Inventors: |
Holl; Christian; (Holland,
MI) ; Binkowski; Joseph; (Holland, MI) ;
Prasoody; Sivanathan; (Holland, MI) |
Correspondence
Address: |
ROBERT J. SAYFIE, P.C.
161 OTTAWA AVENUE NW, SUITE 407
GRAND RAPIDS
MI
49503
US
|
Family ID: |
37766213 |
Appl. No.: |
11/208409 |
Filed: |
August 19, 2005 |
Current U.S.
Class: |
52/843 |
Current CPC
Class: |
E04C 2003/043 20130101;
E04C 3/28 20130101; B60R 2019/182 20130101; B60R 19/18 20130101;
E04C 2003/0465 20130101; E04C 2003/0469 20130101 |
Class at
Publication: |
052/720.1 |
International
Class: |
E04C 3/30 20060101
E04C003/30 |
Claims
1. A gooseneck beam comprising: a body; said body having a first
beam portion that is oriented in a rear plane; said body having a
second beam portion that is oriented in a front plane; a first
gooseneck portion between said first beam portion and said second
beam portion; said body having a third beam portion that is
oriented in said rear plane; and a second gooseneck portion between
said second beam portion and said third beam portion.
2. The gooseneck beam of claim 1, wherein said rear plane is
substantially parallel with said front plane.
3. The gooseneck beam of claim 1, wherein said body has a
substantially rectangular cross sectional configuration.
4. The gooseneck beam of claim 1, wherein said body comprises a
B-shaped cross sectional configuration.
5. The gooseneck beam of claim 1, wherein said body is formed from
aluminum.
6. The gooseneck beam of claim 1, wherein said first gooseneck
portion is generated about a first rear wall radius, a first front
wall radius, a second rear wall radius, and a second front wall
radius.
7. The gooseneck beam of claim 1, wherein said second gooseneck
portion is generated about a second rear wall radius, a second
front wall radius, a third rear wall radius and a third front wall
radius.
8. The gooseneck beam of claim 1, wherein said body is capable of
being secured to a motor vehicle.
9. The gooseneck beam of claim 1, wherein said body is formed from
a process that comprises the steps of: positioning a length of a
material on a flat surface of a two-cam rotating member; gripping
said material with said two-cam rotating member; restraining a
length of said material; rotating said two-cam rotating member to
form a first bend; and pressing of a punch to form a second bend of
the gooseneck.
10. The gooseneck beam of claim 1, wherein said body is formed from
a process that comprises the steps of: positioning extruded
material on flat surfaces of a two cam, rotating block structure;
restraining a cut length of said extruded material to prevent the
tube wall from deforming for some distance from the ends of the cut
length as the blocks begin to rotate about respective pivot
positions; pressing the desired gooseneck portion of said cut
length to form a gooseneck portion; and machining operations to
form bolt hole creation or means for bracket attachment.
11. A gooseneck beam, which comprises: a first beam portion, a
third beam portion, and a second beam portion disposed between said
first beam portion and said third beam portion; said second beam
portion at least partially disposed in a front plane; a rear plane
disposed rearwardly of said front plane; said first beam portion
and said third beam portion each at least partially disposed in
said rear plane; a first gooseneck portion disposed between said
first beam portion and said second beam portion; and a second
gooseneck portion disposed between said second beam portion and
said third beam portion.
12. The gooseneck beam of claim 11, wherein said rear plane is
substantially parallel with said front plane.
13. The gooseneck beam of claim 11, wherein said body has a
substantially rectangular cross sectional configuration.
14. The gooseneck beam of claim 11, wherein said body comprises a
B-shaped cross sectional configuration.
15. The gooseneck beam of claim 11, wherein said body is formed
from aluminum.
16. The gooseneck beam of claim 1, wherein said first gooseneck
portion is generated about a first rear wall radius, a first front
wall radius, a second rear wall radius, and a second front wall
radius.
17. The gooseneck beam of claim 11, wherein said second gooseneck
portion is generated about a second rear wall radius, a second
front wall radius, a third rear wall radius and a third front wall
radius.
18. The gooseneck beam of claim 11, wherein said body is capable of
being secured to a motor vehicle.
19. The gooseneck beam of claim 11, wherein said body is formed
from a process comprising the steps of: positioning a length of a
material on a flat surface of a two-cam rotating member; gripping
said material with said two-cam rotating member; restraining a
length of said material; rotating said two-cam rotating member to
form a first bend; and pressing of a punch to form a second bend of
the gooseneck.
20. The gooseneck beam of claim 11, wherein said body (20) is
formed from a stretch forming process comprising the steps of:
positioning extruded material on flat surfaces of a two cam,
rotating block structure; restraining a cut length of said extruded
material to prevent the tube wall from deforming for some distance
from the ends of the cut length as the blocks begin to rotate about
respective pivot positions; pressing the desired gooseneck portion
of said cut length to form a gooseneck portion; and machining
operations to form bolt hole creation or means for bracket
attachment.
21. A method to form a gooseneck beam, comprising the steps of:
positioning a length of a material on a flat surface of a two-cam
rotating member; gripping said material with said two-cam rotating
member; restraining a length of said material; rotating said
two-cam rotating member to form a first bend; and pressing of a
punch to form a second bend of the gooseneck.
Description
BACKGROUND OF THE INVENTION
[0001] This invention relates to a gooseneck beam and a method to
manufacture a gooseneck beam. Particularly, the present invention
may be a bumper for motor vehicles.
[0002] Motor vehicle beams are used on motor vehicles to absorb
impact and prevent damage to other, usually more costly, components
of the motor vehicle. Due to the worldwide volume of motor vehicle
usage, a decrease in the cost to produce a beam; a decrease in the
weight of a single beam; or a decrease in the production time of a
single beam, can be a significant savings in cost and
resources.
[0003] Further, beams or bumpers that are mounted to motor vehicles
generally require crash boxes and pole protectors. Crash boxes and
pole protectors add cost, increase time of production, and increase
weight to the motor vehicle on which the beam is placed.
[0004] As can be seen, there is a need for a motor vehicle beam or
bumper that can be produced at a reduced cost, reduced production
time, having a reduced weight. There is also a need for a motor
vehicle beam that does not use crash boxes or pole protectors.
[0005] U.S. Patent Application Publication No. 2005/0104393
discloses a bumper reinforcement 2 having various cross sectional
shapes (paragraph [0022]). This also discloses an aluminum bumper
stay 4. This publication does not disclose a gooseneck beam shape.
This publication does not disclose specific dimensions of the
beam.
[0006] U.S. Patent Application Publication No. 2005/0067845
discloses a bumper and deformation element. This discloses an
extruded aluminum bumper. This publication does not disclose a
gooseneck beam shape. This publication does not disclose specific
dimensions of the beam.
SUMMARY OF THE INVENTION
[0007] An aspect of the present invention is a gooseneck beam
comprising a body; said body having a first beam portion that is
oriented in a rear plane; said body having a second beam portion
that is oriented in a front plane; a first gooseneck portion
between said first beam portion and said second beam portion; said
body having a third beam portion that is oriented in said rear
plane; and a second gooseneck portion between said second beam
portion and said third beam portion.
[0008] Another aspect of the present invention is a gooseneck beam,
which comprises a body having a first beam portion, a third beam
portion, and a second beam portion disposed between said first beam
portion and said third beam portion; said second beam portion at
least partially disposed in a front plane; a rear plane disposed
rearwardly of said front plane; said first beam portion and said
third beam portion each at least partially disposed in said rear
plane; a first gooseneck portion disposed between said first beam
portion and said second beam portion; and a second gooseneck
portion disposed between said second beam portion and said third
beam portion.
[0009] Yet another aspect is a method to form a gooseneck beam,
comprising the steps of positioning a length of a material on a
flat surface of a two-cam rotating member; gripping said material
with said two-cam rotating member; restraining a length of said
material; rotating said two-cam rotating member to form a first
bend; and pressing of a punch to form a second bend of the
gooseneck.
[0010] These and other features, aspects and advantages of the
present invention will become better understood with reference to
the following drawings, description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a pictorial view of an exemplary embodiment of a
gooseneck beam of the present invention;
[0012] FIG. 2 is a top view of an exemplary embodiment of the
gooseneck beam of the present invention;
[0013] FIG. 3 is a partial top view of an exemplary embodiment of
the gooseneck beam of the present invention;
[0014] FIG. 4 is a cross sectional view of an exemplary embodiment
of the present invention;
[0015] FIG. 5 is a second cross sectional view of an exemplary
embodiment of the present invention;
[0016] FIG. 6 are schematic representations of various shapes of
different exemplary embodiments of the gooseneck beam of the
present invention;
[0017] FIGS. 7A, 7B, 7C, and 7D illustrate the comparisons of
impact with regard to a prior art beam and the beam of the present
invention;
[0018] FIG. 9 illustrates a method for creating the gooseneck beam
of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The following detailed description is of the best currently
contemplated modes of carrying out the invention. The description
is not to be taken in a limiting sense, but is made merely for the
purpose of illustrating the general principles of the invention,
since the scope of the invention is best defined by the appended
claims.
[0020] FIG. 1 illustrates an exemplary embodiment of the gooseneck
beam, or beam 10 of the present invention. FIG. 2 illustrates an
exemplary embodiment of the gooseneck beam 10 of the present
invention. FIGS. 1 and 2 generally disclose the gooseneck shape of
the beam 10. FIGS. 1 and 2 show a first and second gooseneck
portion 12, 14, respectively. FIG. 3 illustrates a general cross
section of an exemplary embodiment of a cross-section the gooseneck
beam 10.
[0021] As illustrated in FIGS. 1 and 2, an exemplary embodiment of
the present invention may have a first and second gooseneck portion
12, 14. Each gooseneck portion 12, 14 is generated about at least
two radii; each separate radius may be positioned on opposite sides
of the beam 10; and may be tangent to each other. For example,
referring to FIG. 3, the front wall 60, 74 of the first gooseneck
portion 12 may be generated about a first front wall radius 120
that is located forwardly of the beam 10 and a second or middle
front wall radius 140 that is located rearwardly of the beam 10.
The second or middle front wall radius 140 is located between the
first front wall radius 120 and a third front wall radius 160 (seen
in FIG. 2).
[0022] Referring to FIGS. 2 and 3, the rear wall 50 may be
generated about a first rear wall radius 110, which radius 110 and
corresponding origin or centerpoint is disposed forwardly of the
beam 10, and a second (middle) rear wall radius 130, which is
disposed rearwardly of the beam 10, and may be tangent to radius
110. The second (middle) rear wall radius 130 is located between
the first rear wall radius 110 and a third rear wall radius 150,
which may be tangent to said second rear wall radius 130.
[0023] In this description, forwardly refers to a location in front
of the beam 10. It is understood that the beam 10 may be secured to
a motor vehicle with the rear wall 50 facing the motor vehicle, and
the front walls 60, 74 disposed in front, or forwardly of the rear
wall 50. However it is understood that the beam 10 may be
positioned on a motor vehicle in a variety of locational
relationships. For example the beam 10 may be positioned where the
front walls 60, 74 face the motor vehicle, and the rear wall 50 is
in front of the front walls 60, 74, relative to the motor
vehicle.
[0024] Due to the thickness of the beam 10 that is defined by the
distance from the front walls 60, 74 to the rear wall 50; the front
walls 60, 74 and the rear wall 50 may have different radii at any
given gooseneck portion 12, 14. As illustrated in FIGS. 2 and 3,
four (4) radii comprise a single gooseneck portion 12, or 14. For
example a first front wall radius 120 may be about 700 mm, and a
first rear wall radius 110 may be about 800 mm for any single
gooseneck portion 12, 14. A middle or second front wall radius 140
may be about 800 mm, and a middle or second rear wall radius 130
may be about 700 mm. As illustrated in FIG. 3, the first front wall
radius 120 and the first rear wall radius 110 are both disposed
forwardly of the beam 10, and both 120, 110 may have the same
center point or point of origin (not shown). Alternatively, the
center points of radii 120, 110 may not coincide.
[0025] As further illustrated in FIG. 3, the second front wall
radius 140 and second rear wall radius 130 may be disposed
rearwardly of the beam 10, and both radii 140, 130 may have the
same point of origin or center point. Alternatively, the center
points of radii 140, 130 may not coincide.
[0026] As illustrated in FIG. 2, a third front wall radius 160 and
third rear wall radius 150 may be disposed forwardly of the beam,
similar to the first front wall radius 120 and a first rear wall
radius 110. In one exemplary embodiment the first front wall radius
120, the second front wall radius 140, and the third front wall
radius 160 have the same distance. In one exemplary embodiment the
first rear wall radius 110, the second rear wall radius 130, and
the third rear wall radius 150 have the same distance. In one
exemplary embodiment, the first front wall radius 120 and the first
rear wall radius 110 share the same point of origin, which is the
same distance from the point of origin of the second front wall
radius 140 and second rear wall radius 130, as the third front wall
radius 160 and third rear wall radius.
[0027] The dimensions of the gooseneck beam 10 may vary. For
example the beam 10 may be a variety of lengths to accommodate for
the variety in motor vehicle widths. Also, the radii may be varied
depending on the beam depth, which may be defined by the distance
between the front plane 400 and the rear plane 410. The distance
between the front plane 400 and the rear plane 410 may vary. For
example if a beam 10 having a greater depth is desired, the
gooseneck beam 10 may be designed with comparatively lower radii
110, 120, 130, 140, 150, 160.
[0028] The gooseneck beam 10 can be comprised of a variety of cross
sectional shapes and configurations, such as illustrated in FIGS. 4
and 5, and the variety of cross sectional shapes illustrated in
FIG. 6. FIG. 6 illustrates schematics of ten (10) other types of
cross sections of the present invention. The vertical line disposed
on the right of the schematic cross section designates the beam 10
front face.
[0029] FIG. 4 illustrates a cross sectional view of an exemplary
embodiment of a gooseneck beam, or beam 10 of the present
invention. This configuration may be referred to as a B-shaped
configuration. In this exemplary embodiment, the beam 10 has a body
20. The body 20 has a top wall 30 having a top wall rear portion 32
and a top wall front portion 34. A rear wall 50 extends downwardly
from the top wall rear portion 32 to a bottom wall 40. The bottom
wall 40 extends forwardly to a lower front wall 60. The lower front
wall 60 extends upwardly from said bottom wall 40. The lower front
wall 60 extends upwardly to a lower horizontally oriented
transverse wall 62. In the exemplary embodiment as illustrated in
FIG. 3, the lower horizontally oriented transverse wall 62 extends
inwardly and slightly upwardly (or toward the rear wall 50), to a
vertically oriented recessed wall, also referred to an a vertical
recessed wall 70. The vertical recessed wall 70 extending upwardly
to an upper horizontally oriented transverse wall 72. The upper
horizontally oriented transverse wall 72 extending outwardly and
slightly upwardly (or away from the rear wall 50) to an upper front
wall 74, said upper front wall 74 may be oriented in a
substantially vertical plane. The upper front wall 74 extending
upwardly to the top wall front portion 34. A rib 80 extending
rearwardly from a vertical recess wall inside surface 71, to a rear
wall inside surface 52.
[0030] FIG. 4 also illustrates one exemplary embodiment where the
top wall front portion 34 may have a material thickness greater
than that of the top wall rear portion 32. A rib front portion 82
may have a greater material thickness than a rib middle portion 84.
A rib rear portion 86 may have a material thickness that is greater
than that of the rib middle portion 84, and that is less than that
of the rib front portion 82.
[0031] Also illustrated in FIG. 3 is an exemplary embodiment
whereby a bottom wall front portion 44 may have a material
thickness that is greater than that of a bottom wall rear portion
42.
[0032] In one exemplary embodiment the top and bottom walls 30, 40
have a thickness of about 3.5 mm near the front walls 74, 60, and
the top and bottom walls 30, 40 have a thickness of about 2.2 mm
near the rear wall 50. In one exemplary embodiment the rib front
portion is about 3.5 mm thick, the rib middle portion 84 is about
2.2 mm thick, and the rib rear portion 86 is about 2.8 mm thick. In
one exemplary embodiment the front walls 74, 60 are about 4.5 mm
thick. In one exemplary embodiment the horizontal transverse walls
62, 72 are about 4.5 mm thick, and the vertical recessed wall 70 is
about 5.5 mm thick. The rib 80 may connect to the vertical recessed
wall inside surface 71 at a junction where the rib front portion is
about 3.5 mm and the vertical recessed wall 70 is about 5.5 mm in
thickness. In one exemplary embodiment the rib rear portion 86 may
connect to the rear wall 50 at a junction where the rear rib
portion 86 is about 2.8 mm and the rear wall 50 is about 4.2 mm
thick. In one exemplary embodiment the front walls 60, 74 are
disposed from the rear wall 50 by a distance of about 100.35 mm,
which also defines the depth of the beam 10, and the depth of the
top wall 30 and the bottom wall. In one exemplary embodiment the
top wall 30 is disposed from the bottom wall 40 by a distance of
about 110.5 mm, which represents the height of the beam 10. In one
exemplary embodiment, the lower front wall 60, the vertical
recessed wall 70, and the upper front wall 74 each comprise about
1/3 of the beam 10 height. In other word, each the lower front wall
60, the vertical recessed wall 70, and the upper front wall 74 are
each about the same length.
[0033] FIG. 5 illustrates another cross sectional configuration of
the present invention, having a substantially rectangular shell 500
having a rectangular shell rib 510 extending from a rectangular
shell front wall 520 to a rectangular shell rear wall 530, to
define two hollow chambers above and below the rectangular shell
rib 510.
[0034] As illustrated in FIG. 6, the schematic of cross sectional
configurations illustrated in FIGS. 6A, 6E, 6F, 6G, 6H, 6I, and 6J
have the general configuration as described above with reference to
FIG. 3, also referred to as the B-shaped configuration. Thus all of
the illustrated, except for 6B, 6C, 6D have the configuration
described with reference to FIG. 3. In other words, all except for
6B, 6C, and 6D may have a similar relationship with respect to the
top wall 30, the bottom wall 40, the rear wall 50, the upper front
wall 74, the lower front wall 60 and the vertical recessed wall 70.
For example, 6E is representative of the cross sectional
configuration of FIG. 3. FIG. 6F also comprises the representative
cross sectional configuration of FIG. 3, with the additional
component of a substantially vertically oriented panel 210.
[0035] The present invention is not limited to the cross sectional
configuration as illustrated in FIG. 3. For example, as illustrated
in FIG. 6B, the present invention may comprise a forwardly offset
wall 200 instead of a vertical recessed wall 70 (of FIG. 4). And
FIG. 6D is essentially FIG. 6B with a reversing of the front wall
and rear wall. FIG. 6C is a cross sectional configuration of the
present invention having a single front wall 220, a divider rib
230, and the outer housing 240.
[0036] FIGS. 7A, 7B, 7C, and 7D generally illustrate the difference
in beam impact of the present invention when compared to a prior
art beam. FIGS. 7A and 7B illustrate the prior art. FIGS. 7C and 7D
illustrate the present invention. Specifically, the when
encountering an equal force the prior art beam 1 sustains axial
deformation at the location where the prior art beam 1 adjoins the
pole or crash box 2. The present invention beam 10 absorbs the
force near the point of impact 430 rather than distributing the
force to a rail bracket 420.
[0037] The beam 10 may be attached to a motor vehicle by being
bolted or welded to two brackets, one on each end of the beam
10.
[0038] This gooseneck beam 10 may have additional applications
beyond motor vehicle bumpers, such as guardrails or other
structures that are subject to impact.
[0039] In one exemplary embodiment the beam 20 may be comprised of
aluminum. However other materials that can form a rigid structure
can also be used, such as steel, composites, or wood. In one
exemplary embodiment, the beam 10 may be formed from aluminum alloy
6005 T6 or 7108.70 T79. A non-linear stress-strain curve is used
for this aluminum alloy.
[0040] An aluminum gooseneck beam 10 of the present invention may
be formed with the extrusion process--and cooling table--that
displaces a billet of aluminum through a stationary die. The
aluminum displaced through the die may form the cross sectional
shape of FIGS. 3, 4, or 6. When a particular mass of billet
material is extruded through the die, a 50-100 foot long structural
member may be formed. The structural member is then partitioned
into smaller lengths for particular applications. The structural
members are also washed.
[0041] Further, the gooseneck portions 12, 14, may be formed by a
press bending process or a stretch forming process. The press
bending process requires positioning the cut length of extruded
material in a die cavity that has a desired gooseneck profile shape
that the structural member is to take when the forming process is
complete. Next and engaging process is used in which other
structural tooling engages the ends of the cut length to restrain
the structural member to prevent the walls from deforming for some
distance from the ends of the member. Then pressing via a punch
press, which may be located above the die cavity to push the cut
length into the die cavity to form the shape of the structural
member. The factor of springback is incorporated in the die cavity
design. Springback occurs when the punch press is backed away from
the die cavity. Further machining operations may occur in the
forming cell or in subsequent operations to compete the final
processing of the cut length. These may include bolt hole creation,
saw cuts on the ends of the structural member, or bracket
attachment.
[0042] The stretch forming process may also be used to form the
gooseneck beam 10. Here, the cut length of the extruded material is
positioned on flat surfaces of a two cam, rotating block structure.
These rotating block structure have ends with gripping members
capable of restraining the cut length to prevent the tube wall from
deforming for some distance from the ends of the cut length as the
blocks begin to rotate about their respective pivot positions. When
the rotating blocks reach the end of rotation, a press action forms
the secondary bend of the gooseneck. The rotating block structures
must also account for springback. Thus the rotating blocks are
designed to rotate beyond a desired rotation angle. The pivot
points of the rotating blocks are selected to prevent the
structural member walls from buckling and to minimize tube wall
strain. Without proper positioning, buckling may occur at an inside
radius of a gooseneck portion. The inside radius being the wall
that is closer to the radius point of origin. Further machining
operations may be used such as bolt hole creation, saw cut on the
ends of the structural members, or bracket attachment.
[0043] FIG. 9 illustrates an exemplary process 700 to form the
gooseneck beam of the present invention. Generally, the process or
method 700 includes the steps of positioning 710 a length of a
material on a flat surface of a two-cam rotating member. Then
gripping 720 said material with said two-cam rotating member.
Third, restraining 730 a length of said material. Fourth, rotating
740 said two-cam rotating member to form a first bend; and then
pressing 750 of a punch to form a second bend of the gooseneck.
[0044] It should be understood, of course, that the foregoing
relates to exemplary embodiments of the invention and that
modifications may be made without departing from the spirit and
scope of the invention as set forth in the following claims.
* * * * *