U.S. patent application number 16/166584 was filed with the patent office on 2019-02-21 for hitch ball mount and method of forming the hitch ball mount.
The applicant listed for this patent is HORIZON GLOBAL AMERICAS INC.. Invention is credited to Francis Bernart, Thomas DePietro.
Application Number | 20190054783 16/166584 |
Document ID | / |
Family ID | 48082437 |
Filed Date | 2019-02-21 |
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United States Patent
Application |
20190054783 |
Kind Code |
A1 |
Bernart; Francis ; et
al. |
February 21, 2019 |
HITCH BALL MOUNT AND METHOD OF FORMING THE HITCH BALL MOUNT
Abstract
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.
Inventors: |
Bernart; Francis; (North
Canton, OH) ; DePietro; Thomas; (Solon, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
HORIZON GLOBAL AMERICAS INC. |
PLYMOUTH |
MI |
US |
|
|
Family ID: |
48082437 |
Appl. No.: |
16/166584 |
Filed: |
October 22, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15095820 |
Apr 11, 2016 |
10106001 |
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16166584 |
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13649700 |
Oct 11, 2012 |
9308789 |
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15095820 |
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61545878 |
Oct 11, 2011 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B60D 1/52 20130101; B60D
1/06 20130101 |
International
Class: |
B60D 1/06 20060101
B60D001/06; B60D 1/52 20060101 B60D001/52 |
Claims
1. A method of forming a hitch ball mount comprising the steps of:
providing a generally tubular member having first and second end
portions; stamping the tubular member between the first and second
end portions forming a drop portion; and stamping the second end
portion of the tubular member forming at least a portion of a hitch
ball mounting portion.
2. The method of claim 1, wherein forming the drop portion, hitch
receiver portion and hitch ball mounting portion are performed
substantially simultaneously whereby the tubular member, drop
portion and hitch receiver portion are a monolithic unit.
3. The method of claim 1, wherein the steps of stamping the tubular
member include hydro-forming.
4. The method of claim 1, wherein the step of stamping the second
end portion of the tubular member fully forms the hitch ball
mounting portion.
5. The method of claim 1, further comprising the step of forming an
axial through-hole extending through the hitch ball mounting
portion.
6. The method of claim 5, further comprising forming an a circular
recess positioned axially relative to the through-hole with the
through-hole being within the recess.
7. The method of claim 1, wherein forming the portion of the hitch
ball mounting portion forms a cavity.
8. The method of claim 7, further comprising the steps of:
inserting at least one insert into the cavity of the hitch ball
mounting portion; and stamping the hitch ball mounting portion
fully forming the hitch ball mounting portion.
9. The method of claim 1, further comprising the step of grinding
an end portion of the hitch ball mounting portion.
10. The method of claim 1, further comprising the step of attaching
a generally protective layer to an end portion of the hitch ball
mounting portion.
11. The method of claim 10, wherein the step of attaching the
generally protective layer inhibits corrosion at the end portion of
the hitch ball mounting portion.
12. The method of claim 1, wherein the step of attaching the
generally protective layer includes welding the end portion of the
hitch ball mounting portion.
13. A method of forming a hitch ball mount comprising the steps of:
providing a generally tubular member having first and second end
portions; inserting the tubular member into a die; and stamping the
tubular member forming a drop portion and a hitch ball mounting
portion.
14. A method of forming a hitch ball mount comprising the steps of:
providing a generally tubular member having first and second end
portions, wherein the first end portion is selectively attachable
to a hitch receiver of a towing vehicle; inserting the tubular
member into a die; stamping the tubular member between the first
and second end portions forming a drop portion; and stamping the
tubular member at the second end portion forming a hitch ball
mounting portion.
15. The method of claim 14, wherein the steps of stamping the
tubular member between the first and second end portions and the
second end portion are performed generally simultaneously.
16. The method of claim 15, further comprising the step of dwelling
the stamping of the tubular member during stamping the tubular
member between the first and second end portions forming the drop
portion.
17. The method of claim 16, further comprising the step of dwelling
the stamping of the tubular member during stamping the tubular
member at the second end portion forming the hitch ball mounting
portion.
18. A method of forming a hitch ball mount comprising the steps of:
providing a monolithic tubular member having first and second end
portions with a cavity extending between the first and second end
portions; stamping the tubular member between the first and second
end portions forming a drop portion; stamping the tubular member at
the second end portion forming a hitch ball mounting portion; and
generally eliminating the cavity from the hitch ball mounting
portion.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. Utility Patent
Application No. 15/095,820, filed on Apr. 11, 2016, and entitled
"Hitch Ball Mount and Method of Forming the Hitch Ball Mount,"
which is a continuation of U.S. Utility Patent Application No.
13/649,700, now U.S. Pat. No. 9,308,789, entitled "Hitch Ball Mount
and Method of Forming the Hitch Ball Mount" filed on Oct. 11, 2012,
which claims the benefit of U.S. Provisional Patent Application No.
61/545,878 entitled "Stamped Hitch Ball Mount" filed on Oct. 11,
2011, all of which are hereby incorporated in their entirety by
reference.
FIELD OF THE INVENTION
[0002] 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
[0003] 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.
[0004] 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.
[0005] 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.
[0006] 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.
[0007] 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.
[0008] 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
[0009] 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.
[0010] 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.
[0011] 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.
[0012] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Operation of the invention may be better understood by
reference to the following detailed description taken in connection
with the following illustrations, wherein:
[0014] FIG. 1 is a perspective view of embodiments of a hitch ball
mount; FIG. 1A is a perspective view of embodiments of a hitch ball
mount and FIG. 1B is a perspective view of a hitch ball mount
attached with a towing vehicle.
[0015] FIG. 2 is a side view of the hitch ball mount of FIG. 1.
[0016] FIG. 3 is a front view of the hitch ball mount of FIG.
1.
[0017] FIG. 4 is a rear view of the hitch ball mount of FIG. 1.
[0018] FIG. 5 is a top view of the hitch ball mount of FIG. 1.
[0019] FIG. 6 is a bottom view of the hitch ball mount of FIG.
1.
[0020] FIG. 7 is a front perspective view of embodiments of a hitch
ball mount.
[0021] FIG. 8 is a rear perspective view of the hitch ball mount of
FIG. 7.
[0022] FIG. 9 is a side view of the hitch ball mount of FIG. 7.
[0023] FIG. 10 is a front view of the hitch ball mount of FIG.
7.
[0024] FIG. 11 is a rear view of the hitch ball mount of FIG.
7.
[0025] FIG. 12 is top view of hitch ball mount of FIG. 7.
[0026] FIG. 13 is a perspective view of embodiments of a hitch ball
mount.
[0027] FIG. 14 is a perspective view of a tubular member and an
alternative embodiment of a tubular member.
[0028] FIG. 15 is a diagrammatical view of exemplary embodiments of
steps of forming a hitch ball mount.
[0029] FIG. 16 is a front perspective view of embodiments of a
hitch ball mount.
[0030] FIG. 17 is a rear perspective view of the hitch ball mount
of FIG. 16.
[0031] FIG. 18 is a side view of the hitch ball mount of FIG.
16.
[0032] FIG. 19 is a front view of the hitch ball mount of FIG.
16.
[0033] FIG. 20 is a rear view of the hitch ball mount of FIG.
16.
[0034] FIG. 21 is top view of the hitch ball mount of FIG. 16.
[0035] FIG. 22 is a front perspective view of embodiments of a
hitch ball mount.
[0036] FIG. 23 is a rear perspective view of the hitch ball mount
of FIG. 22.
[0037] FIG. 24 is a side view of the hitch ball mount of FIG.
22.
[0038] FIG. 25 is a front view of the hitch ball mount of FIG.
22.
[0039] FIG. 26 is a rear view of the hitch ball mount of FIG.
22.
[0040] FIG. 27 is top view of the hitch ball mount of FIG. 22.
[0041] FIG. 28 is a front perspective view of embodiments of hitch
ball mount.
[0042] FIG. 29 is a rear perspective view of the hitch ball mount
of FIG. 28.
[0043] FIG. 30 is a side view of the hitch ball mount of FIG.
28.
[0044] FIG. 31 is a front view of the hitch ball mount of FIG.
28.
[0045] FIG. 32 is a rear view of the tamped hitch ball mount of
FIG. 28.
[0046] FIG. 33 is top view of the hitch ball mount of FIG. 28.
[0047] FIG. 34 is a front perspective view of embodiments of a
hitch ball mount.
[0048] FIG. 35 is a rear perspective view of the hitch ball mount
of FIG. 34.
[0049] FIG. 36 is a side view of the hitch ball mount of FIG.
34.
[0050] FIG. 37 is a front view of the hitch ball mount of FIG.
34.
[0051] FIG. 38 is a rear view of the hitch ball mount of FIG.
34.
[0052] FIG. 39 is top view of the hitch ball mount of FIG. 34.
[0053] FIG. 40 is a front perspective view of embodiments of a
hitch ball mount.
[0054] FIG. 41 is a rear perspective view of the hitch ball mount
of FIG. 40.
[0055] FIG. 42 is a side view of the hitch ball mount of FIG.
40.
[0056] FIG. 43 is a front view of the hitch ball mount of FIG.
40.
[0057] FIG. 44 is a rear view of the hitch ball mount of FIG.
40.
[0058] FIG. 45 is top view of the hitch ball mount of FIG. 40.
[0059] FIG. 46 is a perspective view of embodiments of a hitch ball
mount including inserts.
[0060] FIG. 47 is a front perspective view of embodiments of a
hitch ball mount.
[0061] FIG. 48 is a rear perspective view of the hitch ball mount
of FIG. 47.
[0062] FIG. 49 is a side view of the hitch ball mount of FIG.
47.
[0063] FIG. 50 is a front view of the hitch ball mount of FIG.
47.
[0064] FIG. 51 is a rear view of the hitch ball mount of FIG.
47.
[0065] FIG. 52 is top view of the hitch ball mount of FIG. 47.
[0066] FIG. 53 is a front perspective view of embodiments of a
hitch ball mount.
[0067] FIG. 54 is a rear perspective view of the hitch ball mount
of FIG. 53.
[0068] FIG. 55 is a side view of the hitch ball mount of FIG.
53.
[0069] FIG. 56 is a front view of the hitch ball mount of FIG.
53.
[0070] FIG. 57 is a rear view of the hitch ball mount of FIG.
53.
[0071] FIG. 58 is top view of the hitch ball mount of FIG. 53.
[0072] FIG. 59 is a top view of embodiments of a hitch ball
mount.
[0073] FIG. 60 is a side view of the hitch ball mount of FIG.
59.
[0074] FIG. 61 is a bottom view of the hitch ball mount of FIG.
59.
[0075] FIG. 62 is a top view of embodiments of a hitch ball
mount.
[0076] FIG. 63 is a side view of the hitch ball mount of FIG.
62.
[0077] FIG. 64 is a bottom view of the hitch ball mount of FIG.
62.
[0078] FIG. 65 is a perspective view of embodiments of a hitch ball
mount.
[0079] FIG. 66 is a perspective view of embodiments of a hitch ball
mount.
[0080] FIG. 67 is a perspective view of embodiments of a portion of
a die for forming a hitch ball mount.
[0081] FIG. 68 is a perspective view of embodiments of a portion of
a die for forming a hitch ball mount.
[0082] FIG. 69 is a perspective view of embodiments of a tubular
member of a hitch ball mount.
[0083] FIG. 70 is a perspective view of embodiments of the tubular
member with a slot.
[0084] FIG. 71 is a perspective view of embodiments of the hitch
ball mount.
[0085] FIG. 72 is a perspective view of embodiments of a tubular
member of a hitch ball mount.
[0086] FIG. 73 is a perspective view of embodiments of a hitch ball
mount.
[0087] FIG. 74 is a perspective view of embodiments of a tubular
member of a hitch ball mount.
[0088] FIG. 75 is a perspective view of embodiments of a hitch ball
mount.
[0089] FIG. 76 is a side view of the hitch ball mount of FIG.
75.
[0090] FIG. 77 is a perspective view of embodiments of a hitch ball
mount.
[0091] FIG. 78 is a side view of the hitch ball mount if FIG.
77.
DETAILED DESCRIPTION
[0092] Reference will now be made in detail to exemplary
embodiments of the present invention, examples of which are
illustrated in the accompanying drawings. It is to be understood
that other embodiments may be utilized and structural and
functional changes may be made without departing from the
respective scope of the invention. Moreover, features of the
various embodiments may be combined or altered without departing
from the scope of the invention. As such, the following description
is presented by way of illustration only and should not limit in
any way the various alternatives and modifications that may be made
to the illustrated embodiments and still be within the spirit and
scope of the invention.
[0093] A hitch ball mount 10 may be utilized to operatively secure
a towing vehicle with a towed vehicle in any appropriate manner.
The hitch ball mount 10 may be formed as a monolithic unit or
otherwise may be integrally formed. The hitch ball mount 10 may
include a hitch receiver attachment portion 14, a drop portion 18
and a hitch ball mount portion or tongue 22, as shown in FIGS. 1-6.
The hitch receiver attachment portion 14 may include a tubular
portion 26. The tubular portion 26 may be of any appropriate shape
such that it may be capable of operatively engaging a hitch
receiver (not shown) in any appropriate manner. By way of a
non-limiting example, the tubular portion 26 may be of a generally
square, rectangular, oval, circular shape or any combination of
such shapes. The tubular portion 26 may include an aperture, or by
way of a non-limiting example a pair of transverse apertures 30
that are located on at least two sides 34 of the tubular portion
26. The tubular portion 26 may further include a generally angled
end portion 35. The angled end portion 35 may make it easier to
load the tubular portion 26 into mating engagement with the
applicable hitch receiver.
[0094] The apertures 30 may be shaped and sized such that when the
hitch receiver attachment portion 14 selectively engages the
trailer hitch receiver (not shown), the trailer hitch receiver may
include correspondingly shaped and sized apertures whereby a pin, a
lock, or the like (not shown) may pass through the apertures 30 to
selectively secure the hitch receiver portion 14 to the trailer
hitch receiver (not shown).
[0095] The drop portion 18 of the hitch ball mount 10 may extend
generally between the hitch receiver attachment portion 14 and the
tongue 22. The drop portion 18 may be of any appropriate distance D
as measured vertically from an upper surface 37 of the receiver
portion 14 to an upper surface 40 of the tongue 22, an example of
which is shown in FIG. 2. In some embodiments, the drop portion 18
may be a zero drop whereby the drop portion 18, the upper surface
37 of the receiver attachment portion 14 and the tongue 22 may be
generally parallel with each other. The appropriate distance D of
the drop portion 18 may be based upon the distance the tongue 22
may be desired to extend from the upper surface 37 of the hitch
receiver attachment portion 14 to account for the use of the hitch
ball mount 10.
[0096] The tongue 22 may extend from the drop portion 18. The
tongue 22 may include a hitch ball aperture 44 positioned on the
upper surface 40 of the tongue 22 and may extend through the tongue
22. The hitch ball aperture 44 may be shaped and sized to receive a
hitch ball 46 with nut 47 that may be selectively engaged with the
tongue 22 in any appropriate manner. Further, the tongue 22 may
include a first recess 51 generally circumscribing the hitch ball
aperture 44 in an upper surface 40 of the tongue 22. Alternatively
or in addition, a second recess 51a may be provided around the
hitch ball aperture 44 in a second face 44a of the tongue 22. The
first and second recesses 51, 51a may have a generally non-circular
shape. By way of a non-limiting example, the first and second
recesses 51, 51a may assume an oval, polygonal, square,
rectangular, hexagonal, and star shape, or a combination thereof.
The first and second recesses 51, 51a may be of a generally
identical shape or may possess different shapes.
[0097] In such embodiments, a hitch ball 63, an example of which is
shown in FIG. 1, having a base 65 and threaded mounting shank 133
(such as shown in FIG. 7) may be capable of being selectively
secured in the hitch ball aperture 44. The base 65 may be
correspondingly sized and shaped to be received and held in at
least one of the first and second recesses 51, 51a. The base 65 may
fit in and generally fill the first or second recess 51, 51a or may
fit in and fill only a portion of the first or second recess 51,
51a.
[0098] A fastener 132 (such as that shown in FIG. 7) may be
provided for engaging the mounting shank 133 and securing the hitch
ball 63 to the hitch ball mount 10, such as by way of a
non-limiting example, the fastener 132 may be a nut 132b and a lock
washer 132a. Alternatively, a self-locking nut may be utilized.
[0099] The hitch ball 63 may be easily and conveniently connected
to the hitch ball mount 10. The mounting shank 133 of the hitch
ball 63 may be aligned with and pushed through the hitch ball
aperture 44 in the tongue 22. As this is done the base 65 of the
hitch ball 63 may be seated in the recess 51, or the second recess
51a, as applicable. Once seated, a sidewall 74 of the recess 51 may
engage a side or sides of the base 65 so as to effectively prevent
the hitch ball 63 from rotating relative to the hitch ball mount
10. The lock washer 132a may be placed over the mounting shank 133
and the nut 132b may then be tightened on that mounting shank 133
to complete the connection. During the tightening process, the
engagement of the base 65 of the hitch ball 63 with the sidewall 74
of the recess 51 may prevent rotation of the hitch ball 63 in the
hitch ball mount 10. This may, therefore, allow connection with a
single tool.
[0100] The hitch ball mount 10 may be integrally formed from a
single tubular member. By way of a non-limiting example, the hitch
ball mount 10 may be formed from a generally hollow tubular member
140, an exemplary embodiment of which is shown in FIG. 14. The
hitch ball mount 10 may 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
mount 10 and 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 mount 10.
[0101] By way of a non-limiting example, the hitch ball mount 10
may be formed from a tubular member 140 such as the generally
square cross-section tubular member shown in FIG. 14. The tubular
member 140, however, is not limited to being a generally square
cross-section as shown. The tubular member 140 may be of any
appropriate shape, such as for example, the tubular member 140 may
be generally rectangular, circular, oval, triangular, hexagonal, or
any other polygonal shape. The tubular member 140 may 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).
[0102] The tubular member 140 may be of any appropriate length. By
way of a non-limiting example, the tubular member 140 may be
approximately 24 inches in length. Although, any appropriate length
tubular member 140 may 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 member
140. 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 member 140 may be formed having the
appropriate length and may not need to be cut to length. The
tubular member 140 may be of any appropriate material, such as
steel by way of a non-limiting example. Further, the tubular member
140 may be cut to include the generally angled end portion 35 as
described above. The generally angled end portion 35 may be formed
by utilizing a saw to cut the end thereof.
[0103] The tubular member 140 may be stamped or otherwise formed so
as to form the hitch ball mount 10. The hitch ball mount 10 may
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 portion 14, drop portion 18 and tongue
22 being a monolithic unit or a single integral piece whereby no
other items may need to be attached thereto. The hitch ball mount
10 may be formed in any appropriate manner. By way of a
non-limiting example, the hitch ball mount 10 may be formed
utilizing the tubular member 140 and stamping, cold forming or
hydro-forming.
[0104] In some embodiments, a tubular member 141 may be generally
circular in cross-section as shown in FIG. 14. In these
embodiments, the receiver attachment portion 14 may be stamped in
the appropriate shape. By way of a non-limiting example, an
appropriate portion of the generally circular cross-sectional
tubular member 141 may be stamped to form a generally rectangular
or square cross-sectional receiver attachment portion 14 that may
be capable of operatively engaging the hitch receiver 28. In these
embodiments, the receiver attachment portion 14 may 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 portion 18 and tongue 22 may be formed through subsequent
operation.
[0105] In some embodiments, the tubular member 140 may be hardened
by any appropriate manner, which may strengthen the metal used to
form the hitch ball mount 10. This hardening may occur before
forming the hitch ball mount 10, after forming the hitch ball mount
10, or both before and after forming the hitch ball mount 10. By
way of a non-limiting example, the tubular member 140 may be work
hardened by any appropriate manner before forming the hitch ball
mount 10, after forming the hitch ball mount 10, or both before and
after forming the hitch ball mount 10. Further yet, the hitch ball
mount 10 may be annealed to change the material properties such
before processing further, after formation or both.
[0106] Once the tubular member 140 is hardened or if it is not to
be hardened until after formation or not hardened at all, the
tubular member 140 may be placed in a die 145 of appropriate shape
and size. The shape and size of the die 145 may depend upon the
size and shape of the hitch ball mount 10 required. In the die 145,
the tubular member 140 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.
[0107] An exemplary embodiment of the die 145 is shown in FIGS.
67-68. In these embodiments, the die 145 may include a bottom die
146, shown in FIG. 67 and a top die 147 shown in FIG. 68. The
bottom die 146 may include a pair of upstanding members 149 that
may hold a portion of the tubular member 140 in the appropriate
position when placed in the die 145. The top die 147 may include a
pair of upstanding members 151, a sloped portion 152, and a
generally planar portion 153. The upstanding members 151 may hold a
portion of the tubular member 140 in the appropriate position when
the top die 147 engaged the bottom die 146, similar to the
upstanding members 149. Further, the sloped portion 152 may form
the drop portion 108 and the generally planar portion 153 may form
the tongue 22.
[0108] In operation of the die 145, the tubular member 140 may be
placed in the die 145 whereby a portion of the tubular member 140
is held in place by the upstanding members 149 of the bottom die
146. The top die 147 may then travel toward the bottom die 146 so
that the top die 147 may engage the tubular member 140. In engaging
the tubular member 140, the upstanding members 149 of the bottom
die 146 and the upstanding members 150 of the top die 147 may
generally hold the tubular member 140 in the appropriate location.
The generally planar portion 153 may engage the tubular member 140
generally forming the tongue 22 and the sloped portion 152 may
engage the tubular member 140 generally forming the drop portion
18. The shape and size of the die 145 may change based upon the
desired shape and attributes of the hitch ball mount 10 required.
By way of a non-limiting example, the slope of the sloped portion
152 of the top die 147 may be increased or decreased depending upon
the required distance D of the drop portion 18.
[0109] Upon stamping of the tubular member 140, the drop portion 18
may be formed. The stamp may engage the tubular member between its
first end and second end portions 142, 144 to form the drop portion
18. During this process, however, the first end portion 142 of the
tubular member 140 may not be stamped such that it forms the hitch
receiver portion 14. In some embodiments, the apertures 30 on the
hitch receiver portion 14 may 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 apertures 30 may be
formed after the hitch ball mount 10 is formed. Further in some
embodiments, the apertures 30 may be formed generally
simultaneously with the formation of the drop portion 18, the
tongue 22, or the hitch ball aperture 44.
[0110] The stamped tubular member 140 with the drop portion 18
formed may be placed in another die. This combination may then be
stamped, which may form a portion of the tongue 22 or
alternatively, may form the entire tongue 22. If only a portion of
the tongue 22 is formed, the stamped combination may be placed in
yet another die to complete the formation of the tongue 22 or may
remain in the same die to form the remainder of the tongue 22.
Alternatively, the stamped tubular member 140 with the drop portion
18 may remain in the die used to form such and the combination may
be further stamped which may form a portion of the tongue 22 or
alternatively, may form the entire tongue 22. If only a portion of
the tongue 22 is formed, the stamped combination may be placed in
another die to complete the formation of the tongue 22 or may
remain in the same die to form the remainder of the tongue 22.
[0111] In some embodiments, the hitch ball aperture 44 may be
formed by placing the hitch ball mount 10 having had the drop
portion 18 and tongue 22 formed into another die and stamping the
tongue 22, which may form the hitch ball mounting aperture 44. In
other embodiments, the hitch ball aperture 44 may be formed
simultaneously with the stamping of the tongue 22. In the
alternative, the hitch ball aperture 44 may be formed by another
process, such as by way of a non-limiting example, it may be
drilled or the like.
[0112] In some embodiments, the tubular member 140 may be placed in
a single die. In this die, the tubular member 140 may be stamped to
form the drop portion 18. The combination may be stamped again to
form at least a portion of the tongue 22, or may form the entire
tongue 22 during the initial stamping process. If the tongue 22 is
not completely formed, the combination may be stamped again to form
the remainder of the tongue 22. This combination may be stamped to
form the hitch ball aperture 44, or alternatively, the hitch ball
aperture 44 may be formed with the tongue 22 during any of the
stamping steps.
[0113] In some embodiments, the tubular member 140 may be placed in
an appropriate die and the tubular member 140 be stamped once to
form the entire hitch ball mount 10, including the drop portion 18,
the tongue 22 and the hitch ball aperture 44. This may result in
the hitch ball mount 10 being formed in a single step.
Alternatively, the hitch ball mount 10 may be formed in progressive
processes, but where the hitch ball mount 10 remains in a single
die.
[0114] Further, the hitch ball mount 10 may be formed through cold
forming. The tubular member 140 may be placed in the appropriate
die without any heating of the tubular member 140 or die. The die
may stamp the tubular member 140 on one side using a dwell press,
for example, the stamp presses on the tubular member 140 within the
die and pressure from the press remains applied to the tubular
member 140 forming the hitch ball mount 10. The tubular member 140
may then be removed from the die, turned over (or the die may just
be turned over) and the other side of the tubular member 140 may 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 tongue 22.
[0115] In some embodiments, the hitch ball mount 10 may 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 member
140 may be placed in a die and formed (with or without the
application of heat) into the hitch ball mount 10 with a
prearranged amount of drop configuration D. This drop configuration
D can be all most negligible to a maximum limited by the
tooling.
[0116] The hitch ball mount 10 being 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 mount 10. Additionally,
forming the hitch ball mount 10 as described above may allow
control of stress paths of the hitch ball mount 10 such that they
may flow through the entire hitch ball mount 10 instead of
occurring at the welds as may occur with the prior art hitch ball
mounts.
[0117] While finishing operations may not be necessary for the
hitch ball mount 10, certain finishing operations may be desired
for purely aesthetical reasons. In some embodiments, an end portion
81 of the tongue 22 may undergo a finishing operation, such as by
way of a non-limiting example welding the end portion 81 to make it
aesthetically pleasing. In addition or alternatively, the end
portion 81 may be ground down or ground smooth to clean the end
portion 81 or to shape the end portion 81 to a desired shape. The
welding and grinding operations, however, may not be necessary. By
way of a non-limiting example, the end portion 81 of the tongue 22
may undergo a non-structural weld to generally improve the
aesthetic appearance of the end portion 81. The end portion 81 may
include a seam 82, which may be the result of the stamping process
described above. The seam 82 may have added thereto a protective
layer, such as adding a non-structural weld thereon. This may
provide a generally smooth finish to the end portion 81 and may
generally reduce or eliminate the seam 82.
[0118] Further still, the end portion 81 may be resisted welded,
which may generally eliminate the seam 82. After being stamped as
described above, the seam 82 on the end portion 81 may undergo
resistance welding, which may generally eliminate or reduce the
seam 82. This may further hold together the seam 82, which may also
generally protect interior components of the hitch ball mount 10
from the environment. This may generally prevent premature
degradation of the materials of the hitch ball mount 10.
[0119] In some embodiments, the tubular member 140A may be bent
into a generally lazy S-formation as shown in FIG. 13 before
stamping. Any appropriate method may be used to bend the tubular
member 140A, such as by way of a non-limiting example, cold forming
or mandrel bending the tubular member 104A. 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 portion 14, the drop portion 18 and the
tongue 22 once stamped. By way of a non-limiting example, a top of
the bent generally S-shaped tubular member 140 may form the hitch
receiver portion 14, a middle portion of the generally S-shaped
bent tubular member 140 may form the drop portion 18 and a bottom
of the generally S-shaped bent tubular member 140 may form the
tongue 22. Once the tubular member 140A is bent, it may be stamped
as indicated above. In some embodiments, while cold-forming and/or
prior to cold-forming the tubular member 140A may be heated
slightly to reduce work hardening. The cold-forming may work harden
the tubular member 140A.
[0120] Some exemplary methods for forming the hitch ball mount 10
are shown in FIG. 15. As shown in step 170, the tubular member 140
may be provided. The tubular member 140 may be placed in a die, as
shown in step 172. Next, the tubular member 140 may be stamped as
shown in step 174--the stamping may dwell on the tubular member 140
to further form the hitch ball mount 10. Stamping the tubular
member 140 may form the drop portion 18 as shown in step 176. The
tubular member 140 may then be removed from the die and may be
placed in a second die as shown in step 178. The tubular member 140
with drop portion 18 may then be stamped as shown in step 180--the
stamping may dwell on the tubular member 140 to further form the
tongue 22. This stamping may form the tongue 22 as shown in step
182. The formed hitch ball mount 10 may be removed from the die as
shown in step 184.
[0121] Further, as shown in box 170 the tubular member 140 may be
provided. The tubular member 140 may be cold formed as shown in
step 186. The tubular member 140 may be placed in a die, as shown
in step 188. Next, the tubular member 140 may be stamped as shown
in step 190--the stamping may dwell on the tubular member 140 to
further form the hitch ball mount 10. Stamping the tubular member
140 may form the drop portion 18 as shown in step 192. The tubular
member 140 may then be removed from the die and may be placed in a
second die as shown in step 194. The tubular member 140 with drop
portion 18 may then be stamped as shown in step 196--the stamping
may dwell on the tubular member 140 to further form the tongue 22.
This stamping may form the tongue 22 as shown in step 198. The
formed hitch ball mount 10 may be removed from the die as shown in
step 199.
[0122] 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 member 140 and may
possess the appropriate dies and stamping mechanism to form the
remainder of the hitch ball mount 10.
[0123] 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.
[0124] A hitch ball mount 100 may include a hitch receiver
attachment portion 104, a drop portion 108 and a hitch ball mount
portion or tongue 112 as shown in FIGS. 7-12. The hitch receiver
attachment portion 104 may include a tubular portion 116. The
tubular portion 116 may 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 portion 116 may be generally
square, rectangular, oval, circular shape or any combination of
such shapes. The tubular portion 116 may include an aperture, or by
way of a non-limiting example a pair of transverse apertures 120
that are located on at least two sides 124 of the tubular portion
116.
[0125] The apertures 120 may be shaped and sized such that when the
hitch receiver attachment portion 104 selectively 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 apertures 120 to selectively secure the
hitch receiver portion 104 to the trailer hitch receiver. Further,
any appropriate method and apparatus may be used to selectively
secure the hitch receiver portion 104 to the trailer hitch
receiver.
[0126] The drop portion 108 of the hitch ball mount 100 may extend
between the hitch receiver attachment portion 104 and the tongue
112. The drop portion 108 may be of any appropriate distance D as
measured vertically from an upper surface 105 of the receiver
portion 104 to an upper surface 130 of the tongue 112, an example
of which is shown in FIG. 9. In some embodiments, the drop portion
108 may be a zero drop whereby the drop portion 108, the upper
surface 105 of the receiver attachment portion 104 and the tongue
112 may be generally parallel with each other. The appropriate
distance D of the drop portion 108 may be based upon the distance
the tongue 112 may be desired to extend from the upper surface 105
of the hitch receiver attachment portion 104 to account for the use
of the hitch ball mount 100.
[0127] The tongue 112 may extend from the drop portion 108. The
tongue 112 may include a hitch ball aperture 134 positioned on the
upper surface 130 of the tongue 112 and may extend through the
tongue 112. The hitch ball aperture 134 may be shaped and sized to
receive a hitch ball 131 with a fastener 132 that may be
selectively engaged with the tongue 112 in any appropriate manner.
By way of a non-limiting example, the hitch ball 131 may include a
base 175 and a threaded member 133 extending from the base 175. The
threaded member 133 may pass through the hitch ball aperture 134
and a nut 132b may threadingly engage the threaded member 133
securing the hitch ball 131 to the tongue 112. In addition, the
lock washer 132a may be inserted onto the threaded member 133.
[0128] The hitch ball mount 100 may be integrally formed from a
single tubular member. By way of a non-limiting example, the hitch
ball mount 100 may be formed from a generally hollow tubular member
140, an exemplary embodiment of which is shown in FIG. 14. The
hitch ball mount 100 may 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
mount 100 and 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 mount 100.
[0129] The tubular member 140 may be stamped or otherwise formed so
as to form the hitch ball mount 100. The hitch ball mount 100 may
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 portion 104, drop portion 108
and tongue 112 being a single integral piece or monolithic unit
whereby no other items may need to be attached thereto. The hitch
ball mount 100 may be formed in any appropriate manner. By way of a
non-limiting example, the hitch ball mount 100 may be stamped from
the tubular member 140 or may be hydro-formed.
[0130] In some embodiments, the tubular member 141 may be generally
circular in cross-section as shown in FIG. 14. In these
embodiments, the receiver attachment portion 104 may be stamped in
the appropriate shape. By way of a non-limiting example, an
appropriate portion of the generally circular cross-sectional
tubular member 141 may be stamped to form a generally rectangular
or square cross-sectional receiver attachment portion 104 that may
be capable of operatively engaging a hitch receiver. In these
embodiments, the receiver attachment portion 104 may 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 portion 108 and tongue 112 may be formed through subsequent
operation.
[0131] In some embodiments, the tubular member 140 may be hardened
by any appropriate manner, which may strengthen the metal used to
form the hitch ball mount 100. This hardening may occur before
forming the hitch ball mount 100, after forming the hitch ball
mount 100, or both before and after forming the hitch ball mount
100. By way of a non-limiting example, the tubular member 140 may
be work hardened by any appropriate manner before forming the hitch
ball mount 100, after forming the hitch ball mount 100, or both
before and after forming the hitch ball mount 100. Further yet, the
hitch ball mount 100 may be annealed to change the material
properties such before processing further, after formation or
both.
[0132] Once the tubular member 140 is hardened or if it is not to
be hardened until after formation or not hardened at all, the
tubular member 140 may be placed in a die 145 of appropriate shape
and size. The shape and size of the die 145 may depend upon the
size and shape of the hitch ball mount 100 required. In the die
145, the tubular member 140 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.
[0133] Upon stamping of the tubular member 140, the drop portion
108 may be formed. The stamp may engage the tubular member 140
between its first end and second end portions 142, 144 to form the
drop portion 108. During this process, however, the first end
portion 142 of the tubular member 140 may not be stamped such that
it forms the hitch receiver portion 104. In some embodiments, the
apertures 120 on the hitch receiver portion 104 may 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
apertures 120 may be formed after the hitch ball mount 100 is
formed. Further in some embodiments, the apertures 120 may be
formed generally simultaneously with the formation of the drop
portion 108, the tongue 112, or the hitch ball aperture 134.
[0134] The stamped tubular member 140 with the drop portion 108
formed may be placed in another die. This combination may then be
stamped, which may form a portion of the tongue 112 or
alternatively, may form the entire tongue 112. If only a portion of
the tongue 112 is formed, the stamped combination may be placed in
yet another die to complete the formation of the tongue 112 or may
remain in the same die to form the remainder of the tongue 112.
Alternatively, the stamped tubular member 140 with the drop portion
108 may remain in the die used to form such and the combination may
be further stamped which may form a portion of the tongue 112 or
alternatively, may form the entire tongue 112. If only a portion of
the tongue 112 is formed, the stamped combination may be placed in
another die to complete the formation of the tongue 112 or may
remain in the same die to form the remainder of the tongue 112
[0135] In some embodiments, the hitch ball aperture 134 may be
formed by placing the hitch ball mount 100 having had the drop
portion 108 and tongue 112 formed into another die and stamping the
tongue 112, which may form the hitch ball mounting aperture 134. In
some embodiments, the hitch ball aperture 134 may be formed
simultaneously with the stamping of the tongue 112. In the
alternative, the hitch ball aperture 134 may be formed by another
process, such as by way of a non-limiting example, it may be
drilled or the like.
[0136] In some embodiments, the tubular member 140 may be placed in
a single die. In this die, the tubular member 140 may be stamped to
form the drop portion 108. The combination may be stamped again to
form at least a portion of the tongue 112, or may form the entire
tongue 112 during the initial stamping process. If the tongue 112
is not completely formed, the combination may be stamped again to
form the remainder of the tongue 112. This combination may be
stamped to form the hitch ball aperture 134, or alternatively, the
hitch ball aperture 134 may be formed with the tongue 112 during
any of the stamping steps.
[0137] In some embodiments, the tubular member 140 may be placed in
an appropriate die and the tubular member 140 be stamped once to
form the entire hitch ball mount 100, including the drop portion
108, the tongue 112 and the hitch ball aperture 134. This may
result in the hitch ball mount 100 being formed in a single step.
Alternatively, the hitch ball mount 100 may be formed in
progressive processes, but where the hitch ball mount 100 remains
in a single die.
[0138] In some embodiments, the hitch ball mount 100 may 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 member
140 may be placed in a die and formed (with or without the
application of heat) into the hitch ball mount 100 with a
prearranged amount of drop configuration D. This drop configuration
D can be all most negligible to a maximum limited by the
tooling.
[0139] The hitch ball mount 100 being 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 mount 100. Additionally,
forming the hitch ball mount 100 as described above may allow
control of stress paths of the hitch ball mount 100 such that they
may flow through the entire hitch ball mount 100 instead of
occurring at the welds as may occur with the prior art hitch ball
mounts.
[0140] While finishing operations may not be necessary for hitch
ball mount 100, certain finishing operations may be desired for
purely aesthetical reasons. In some embodiments, an end portion 150
of the tongue 112 may undergo a finishing operation, such as by way
of a non-limiting example non-structural welding the end portion
150 to make it aesthetically pleasing. In addition or
alternatively, the end portion 150 may be ground down or ground
smooth to clean the end portion 150 or to shape the end portion 150
to a desired shape. The welding and grinding operations, however,
may not be necessary.
[0141] In some embodiments, the tubular member 140A may be bent
into a generally lazy S-formation as shown in FIG. 13 before
stamping. Any appropriate method may be used to bend the tubular
member 140A, such as by way of a non-limiting example, cold forming
or mandrel bending the tubular member 104A. 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 portion 104, the drop portion 108 and the
tongue 112 once stamped. By way of a non-limiting example, a top of
the bent generally S-shaped tubular member 140 may form the hitch
receiver portion 104, a middle portion of the generally S-shaped
bent tubular member 140 may form the drop portion 108 and a bottom
of the generally S-shaped bent tubular member 140 may form the
tongue 112. Once the tubular member 140A is bent, it may be stamped
as indicated above. In some embodiments, while cold-forming and/or
prior to cold-forming the tubular member 140A may be heated
slightly to reduce work hardening. The cold-forming may work harden
the tubular member 140A.
[0142] In the alternative, the hitch ball mount 100A may be formed
solely by bending the tubular member 140A and not stamping further.
In these embodiments, the tubular member 140A may be bent in a
generally S-shape to form the hitch receiver portion 104A, the drop
portion 108A and the tongue 112A. By way of a non-limiting example,
a top of the bent generally S-shaped tubular member 140A may form
the hitch receiver portion 104A, a middle portion of the generally
S-shaped bent tubular member 140A may form the drop portion 108A
and a bottom of the generally S-shaped bent tubular member 140A may
form the tongue 112A. In this embodiment, the tongue 112A may not
have a flattened end portion 150A, or in the alternative may have a
flattened end portion similar to the embodiment shown in FIGS.
1-6.
[0143] A hitch ball mount 200 shown in FIGS. 16-21 may 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 mount 200. The hitch ball mount 200 may be formed as
described above. The larger drop/rise distance D, however, may
require that the drop portion 208 be 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 mount 200 may likewise be formed as
describe above.
[0144] A hitch ball mount 300 shown in FIGS. 22-27 may be formed
with a shape that differs from the hitch ball mount 100.
Specifically, the hitch receiver portion 304 may have a more
generally square cross-sectional shape and the tongue 312 may have
a different shape. Further, the drop portion 308 may have a
different shape. The hitch ball mount 300 may be used with
different shaped and sized trailer hitch receivers. The remainder
of the hitch ball mount 300 may be formed as describe above. The
dies to form such, however, may be of a different shape and
sizes.
[0145] In some embodiments, a hitch ball mount 400 may have a
tubular portion 416 that includes walls 455 that are generally
thicker as shown in FIGS. 28-33. The hitch ball mount 400 having
these thicker walls 455 may be formed as set forth above. The hitch
ball mount 400 having thicker walls 455 may result in the hitch
ball mount 400 being of a more robust construction so that it may
be rated for higher classes of towing. As shown in FIGS. 28-33 the
walls 455 being thicker may result in the tongue 412 being
thicker--further resulting in a robust construction. Alternatively,
however, the tongue 412 may not result in being thicker.
[0146] In some embodiments, a hitch ball mount 500 may have a
tubular portion 516 that includes walls 555 that are generally
thicker as shown in FIGS. 34-39. The hitch ball mount 500 may be
formed as set forth above. The hitch ball mount 500 having thicker
walls 555 may result in the tongue 512 being wider as indicated by
W in FIG. 37. The wider tongue 512 may be desired depending upon
the use of the hitch ball mount 500, and may result in the hitch
ball mount 500 being of a more robust construction so that it may
be rated for higher classes of towing.
[0147] In some embodiments shown in FIGS. 40-46, a hitch ball mount
600 may include an insert 662 positioned in the tongue 612, which
may strengthen the hitch ball mount 600. 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 insert 662 may be
used in addition to or in lieu of having thicker walls of the
tubular portion 616. In some embodiments, an insert 662 of any
appropriate shape, size and material may be inserted into the
tubular member 640, such as for example in a second end portion 644
of the tubular member 640. The insert 662 may be inserted into the
tubular member 640 at any appropriate time during the forming
process. By way of a non-limiting example, the insert 662 may be
added to the tubular member 640 before it may be cold-formed, such
as when bent into a generally S shape. In another non-limiting
example, the insert 662 may be inserted into the tubular member 640
after the tubular member 640 may be cold-formed. The tubular member
640 with the insert 662 inserted therein may be placed into a die
and may be stamped to form the tongue 612. When stamped, the insert
662 may be sandwiched within the end portion 650 of the tongue 612.
The insert 662 may be of a material that is harder than the tubular
member 640. The insert 662 may act as an inner die that may not
generally deform during stamping. This may increase the overall
load capacity of the hitch ball mount 600.
[0148] Alternatively, a portion of the tongue 612 may be formed by
way of non-limiting examples, cold-forming, stamping or a
combination of both to form a cavity 663 shown in FIG. 46. Once the
cavity 663 may be formed the insert 662 may be inserted within the
cavity 663. The combination with the insert 662 in the cavity 663
may be placed in a die and stamped. This may result in the insert
662 being sandwiched at the end portion 650 of the tongue 612.
[0149] Alternatively, the insert 662 may be inserted within a die
to form the tongue 612 with insert 662. In these embodiments, the
tubular member 640 may be cold-formed, stamped or both. The insert
662 may be added to the die before or after cold-forming or before
or after stamping of the tubular member. Once the insert 662 is in
the die, immediately before stamping the tubular member 640, the
insert 662 may be positioned within the tubular member 640, such as
by way of a non-limiting example, in the second end portion 644 of
the tubular member 640 and/or the cavity 663. The combination of
the insert 662 and tubular member 640 may be stamped to form the
tongue 612 with insert 662.
[0150] The insert 662 may be any appropriate shape or size and are
not limited to those shown in FIG. 46. By way of a non-limiting
example, the insert 662 may be a single rectangular box of metal or
it could be two or more pieces of metal that may be sandwiched in
the tongue 612 during forming. By way of another non-limiting
example, an insert 664 may be a single rectangular box of metal
that includes an aperture 668 that may correspond with the hitch
ball aperture 634 of the tongue 612. In this embodiment, the insert
664 may be sandwiched in the tongue 612 whereby forming the hitch
ball aperture 634 may not require stamping, drilling or the like,
the insert 664 as the aperture 668 is already formed therein. In
some embodiments, a plurality of inserts may be used in association
with the tongue 612 such 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
shape 669, as shown in FIG. 46.
[0151] Utilizing the inserts 662, 664, 669 may permit the tubular
member 640 to have a thinner sidewall 655 while retaining the
required strength. In these embodiments, the inserts 662, 664, 669
may be steel or another material. In some non-limiting examples,
the inserts 662, 664, 669 may 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 member 640, or may be of a
material that has generally different strength properties than the
tubular member 640. The inserts 662, 664, 669 may provide the
tongue 612 with added strength, which may make the hitch ball mount
600 more robust--resulting in it being capable of being used with
higher classes of towing or heavier towing. The hitch ball mount
600 may otherwise be formed as describe above. The hitch ball mount
600 may include a drop portion 608 and may include a stepped wall
677 that may be positioned between the drop portion 608 and the
tongue 612. The stepped wall 677 may be capable of engaging a hitch
ball such as the base 175 of the hitch ball 131. In these
embodiments, the stepped wall 677 engaging the base 175 of the
hitch ball 131 may generally prevent rotation of the hitch ball 131
during installation thereof on to the hitch ball mount 600. More
specifically, the stepped wall 677 may generally prevent the hitch
ball 131 from rotating while the fastener 132 is being engaged with
the threaded member 133 of the hitch ball 131 during
installation.
[0152] In some embodiments, such as those shown in FIGS. 47-52, a
hitch ball mount 700 may include a hitch ball aperture 734 provided
in the tongue 712. A recess 772 may be provided around the hitch
ball aperture 734 in an upper surface 730 or face of the tongue
712. Alternatively or in addition, a second recess (not shown) may
be provided around the hitch ball aperture 734 in a second face 781
of the tongue 712. The recess 772 may have a generally non-circular
shape. By way of a non-limiting example, the recess 772 may 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 recess 772 and the second recess may be of a generally
identical shape or may possess different shapes.
[0153] In these embodiments, a hitch ball 831, an example of which
is shown in FIG. 53, having a base 875 and threaded mounting shank
833 may be capable of being selectively secured in the hitch ball
aperture 734. The base 875 may be correspondingly sized and shaped
to be received and held in at least one of the recess 772 and/or
the second recess. Thus, the base 875 may fit in and generally fill
the recess 772.
[0154] A fastener 832 may be provided for engaging the shank 833
and securing the hitch ball 831 to the hitch ball mount 700, such
as by way of a non-limiting example, the fastener 833 may be a nut
833 and a lock washer 837. Alternatively, a self-locking nut may be
utilized.
[0155] The hitch ball 831 may be easily and conveniently connected
to the hitch ball mount 700. The mounting shank 833 of the hitch
ball 831 may be aligned with and pushed through the hitch ball
aperture 734 in the tongue 712. As this is done the base 875 of the
hitch ball 831 may be seated in the recess 772. Once seated, a
sidewall 774 of the recess 772 may engage a side or sides of the
base 875 so as to effectively prevent the hitch ball 831 from
rotating relative to the hitch ball mount 700. The lock washer 837
may be placed over the mounting shank 833 and the nut 832 may then
be tightened on that mounting shank 833 to complete the connection.
During the tightening process, the engagement of the base 875 of
the hitch ball 831 with the sidewall 774 of the recess 772 may
generally prevent rotation of the hitch ball 831 in the hitch ball
mount 700 and therefore may allow connection with a single
tool.
[0156] In some embodiments, the hitch ball mount 700 may be
utilized with the tongue 712 directed downward or upward, i.e., the
drop portion 708 may either extend downward as is shown in FIG. 49
or may extend upward. By way of a non-limiting example, the tongue
712 may include a recess 772 and a second recess (not shown) on
each of the faces 730, 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 mount 700 may be capable of
selectively attaching to a hitch receiver in a first position
whereby the first face 730 faces upward and the second face 781
faces downward and a second position whereby the second face 781
faces upward and the first face 730 faces downward.
[0157] In this embodiment, an insert 762 may be utilized to help
form the recess 774. The insert 762 may be of any appropriate shape
and size. By way of a non-limiting example, rods 791 may be
inserted into edges 753 of the second end portion 750 of the tongue
716. The rods 719 may be used to better hold the sidewall 774 of
the recess 772 to form the non-circular recesses. The hitch ball
mount 700 may otherwise be formed as described above.
[0158] In some embodiments, such as those shown in FIGS. 53-58, a
hitch ball mount 800 may include a hitch ball aperture 834 provided
in the tongue 812. The hitch ball aperture 834 may be capable of
operatively attaching a hitch ball 831 with a nut 832. In some
embodiments, a recess 872 may be provided around the hitch ball
aperture 834 in an upper surface 830 or face of the tongue 812.
Alternatively or in addition, a second recess (not shown) may be
provided around the hitch ball aperture 834 in a second face 881 of
the tongue 812.
[0159] The recess 872 may have a generally non-circular shape. By
way of a non-limiting example, the recess 872 may 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 recess 872 and the second recess may be generally
identical or may possess different shapes. This may allow the hitch
ball mount 800 to be selectively attachable to a hitch receiver in
a first and second position. The recess 872 may engage a base 875
of the hitch ball 831 to prevent rotation of the hitch ball 831
during installation thereof onto the tongue 812. More specifically,
the base 875 may engage the recess 872 to prevent rotation of the
hitch ball 831 while the nut 832 may be screwed onto the hitch ball
831.
[0160] In some embodiments, a hitch ball mount 900 may be formed
from a generally planar plate as shown in FIGS. 59-61. In these
embodiments, the generally planar plate may be stamped to form the
hitch ball mount 900. 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 mount 900 required. 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.
[0161] Upon stamping of the generally planar plate, the hitch
receiver portion 904, the drop portion 908, and tongue 912 may all
be formed. Apertures 920 on the hitch receiver portion 904 may be
formed in advance by any suitable process, such as by way of a
non-limiting example, stamping, drilling or the like. The apertures
920 may be formed after the hitch ball mount 900 is formed.
Further, the apertures 920 may be formed generally simultaneously
with the formation of the hitch receiver portion 904, the drop
portion 908, the tongue 912, and/or the hitch ball aperture
934.
[0162] The hitch receiver portion 904, the drop portion 908, and
tongue 912 may be formed generally simultaneously or may be formed
in progressive steps. In addition, a hitch ball aperture 934 may be
formed by stamping the tongue 912 generally simultaneously with the
remainder of the hitch ball mount or may by formed as part of a
progressive step. In addition, the hitch ball aperture 934 may be
formed by another process, such as by way of a non-limiting
example, it may be drilled or the like.
[0163] The drop portion 908 may be formed with any appropriately
sized drop/rise configuration 926, which may also include a zero
drop whereby the hitch receiver portion 904, the drop portion 908
and the tongue 912 may be generally planar. The drop/rise
configuration 926 may be controlled by the size of the generally
planar plate used, how much the drop portion 908 is displaced when
stamped, or by any combination of such.
[0164] In some embodiments, a hitch ball mount 1000 may be formed
from a generally planar plate as shown in FIGS. 62-64. In these
embodiments, the generally planar plate may be stamped to form the
hitch ball mount 1000. 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 mount 1000 required. 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.
[0165] Upon stamping of the generally planar plate, the hitch
receiver portion 1004, the drop portion 1008, and tongue 1012 may
all be formed. Apertures 1020 on the hitch receiver portion 1004
may be formed in advance by any suitable process, such as by way of
a non-limiting example, stamping, drilling or the like. The
apertures 1020 may be formed after the hitch ball mount 1000 is
formed. Further, the apertures 1020 may be formed generally
simultaneously with the formation of the hitch receiver portion
1004, the drop portion 1008, the tongue 1012, and/or the hitch ball
aperture 1034.
[0166] The hitch receiver portion 1004, the drop portion 1008, and
tongue 1012 may be formed generally simultaneously or may be formed
in progressive steps. In addition, a hitch ball aperture 1034 may
be formed by stamping the tongue 1012 generally simultaneously with
the remainder of the hitch ball mount or may by formed as part of a
progressive step. In addition, the hitch ball aperture 1034 may be
formed by another process, such as by way of a non-limiting
example, it may be drilled or the like.
[0167] The drop portion 1008 may be formed with any appropriately
sized drop/rise configuration 1026. The drop/rise configuration
1026 may be controlled by the size of the generally planar plate
used, how much the drop portion 1008 is displaced when stamped, or
by any combination of such.
[0168] In embodiments shown in FIG. 65, a hitch ball mount 1100 may
include a hitch receiver portion 1104, a drop portion 1108, and a
tongue 1112; all of which may be formed by stamping as described
above. The tongue 1112 may include first and second end portions
1187, 1189 respectively. These end portions 1187, 1189 may include
generally bent portions 1194, 1196 that may likewise be formed by
stamping. The bent portions 1194, 1196 may be formed simultaneously
with the stamping that may form the hitch receiver portion 1104,
drop portion 1108, and/or tongue 1112. Alternatively, the bent
portions 1194, 1196 may be formed in a progressive step such as by
way of a non-limiting example stamping the tongue 1112. As shown in
FIG. 65, the tongue 1112 may include a hitch ball aperture 1134,
which may be formed as described above.
[0169] In embodiments shown in FIG. 66, a hitch ball mount 1200 may
include a hitch receiver portion 1204, a drop portion 1208, and a
tongue 1212; all of which may be formed by stamping as described
above. The tongue 1212 may include first and second end portions
1287, 1289 respectively. These end portions 1287, 1289 may include
generally bent portions 1294, 1296 that may likewise be formed by
stamping. The bent portions 1294, 1296 may be formed simultaneously
with the stamping that may form the hitch receiver portion 1204,
drop portion 1208, and/or tongue 1212. Alternatively, the bent
portions 1294, 1296 may be formed in a progressive step such as by
way of a non-limiting example stamping the tongue 1212. As shown in
FIG. 66, the tongue 1212 may include a hitch ball aperture 1234,
which may be formed as described above. In these embodiments,
inserts 1291 may be used and may be sandwiched in the tongue 1212
as described above. The shape and size of the inserts 1291 may be
such that generally raised longitudinal members 1297 may be formed
on an upper surface 1230 of the tongue 1212.
[0170] A hitch ball mount 1300 may be formed from generally hollow
tubular member 1340 as shown in FIGS. 69-71. In these embodiments,
a portion 1341 of the generally hollow tubular member 1340 may be
removed by any appropriate manner, such as for example cutting,
machining a groove or otherwise generally removing the portion 1341
of the tubular member 1340. Once the portion 1341 is removed from
the generally hollow tubular member 1340, the generally hollow
tubular member 1340 may be stamped to form a hitch ball mount 1300.
Removing the portion 1341 may generally remove or eliminate the
stresses in a side wall 1365 of the hitch ball mount 1300 when
stamped.
[0171] The portion 1341 removed from the tubular member 1340 may be
of any appropriate shape and size. By way of a non-limiting
example, the portion 1341 may be of any appropriate width. Further,
the portion 1341 removed from the tubular member 1340 may be
generally linear, s-shape, arched, or the like. By way of a
non-limiting example, the portion 1341 may be a hole, a slit, a
slotted hole, or a slot of any profile. The portion 1341 removed
from the tubular member 1340 may be in any portion of the sidewall
1365; it is not limited to the general center of the tubular member
1340 as shown in FIG. 70. The portion 1341 removed from the tubular
member 1340 may be formed in any appropriate manner. By way of a
non-limited example, the removed portion 1341 may be cut with a
saw, mill, plasma cutter, water jet, laser, or the like.
[0172] Upon stamping of the tubular member 1340 with the removed
portion 1341, the hitch receiver portion 1304, the drop portion
1308, and tongue 1312 may all be formed. As shown in FIG. 71, the
tubular member 1340 may be stamped so that the location of the
removed portion 1341 may form the drop portion 1308 and the tongue
1312. The hitch receiver portion 1304, the drop portion 1308, and
tongue 1312 may be formed generally simultaneously or may be formed
in progressive steps. In addition, a hitch ball aperture 1334 may
be formed by stamping the tongue 1312 generally simultaneously with
the remainder of the hitch ball mount or may by formed as part of a
progressive step. In addition, the hitch ball aperture 1334 may be
formed by another process, such as by way of a non-limiting
example, it may be drilled or the like.
[0173] In some embodiments, a hitch ball mount 1400 may be formed
from generally hollow tubular member 1440 as shown in FIGS. 72 and
73. In these embodiments, a portion 1441 of the generally hollow
tubular member 1440 may be removed by any appropriate manner, such
as for example cutting, machining a groove or otherwise generally
removing the portion 1441 of the tubular member 1440. Once the
portion 1441 is removed from the generally hollow tubular member
1440, the generally hollow tubular member 1440 may be stamped to
form a hitch ball mount 1400. Removing the portion 1441 may
generally remove or eliminate the stresses in a side wall 1465 of
the hitch ball mount 1400 when stamped.
[0174] The portion 1441 removed from the tubular member 1440 may be
of any appropriate shape and size. By way of a non-limiting
example, the portion 1441 may be of any appropriate width. Further,
the portion 1441 removed from the tubular member 1440 may be
generally linear, s-shape, arched, or the like. By way of a
non-limiting example, the portion 1441 may be a hole, a slit, a
slotted hole, or a slot of any profile. The portion 1441 removed
from the tubular member 1440 may be in any portion of the sidewall
1465; it is not limited to the general center of the tubular member
1440 as shown in FIG. 72. The portion 1441 removed from the tubular
member 1440 may be formed in any appropriate manner. By way of a
non-limited example, the removed portion 1441 may be cut with a
saw, mill, plasma cutter, water jet, laser, or the like. The
removed portion 1441 may be positioned at any appropriate position
along with tubular member 1440. It may be positioned in proximity
to an end portion thereof, but may not extend all the way to the
end as shown.
[0175] Upon stamping of the tubular member 1440 with the removed
portion 1441, the hitch receiver portion 1404, the drop portion
1408, and tongue 1412 may all be formed. As shown in FIG. 74, the
tubular member 1440 may be stamped so that the location of the
removed portion 1441 may form the drop portion 1408 and a portion
of the tongue 1412, but may not extend to an end of the tongue
1412. The hitch receiver portion 1404, the drop portion 1408, and
tongue 1412 may be formed generally simultaneously or may be formed
in progressive steps. In addition, a hitch ball aperture 1434 may
be formed by stamping the tongue 1412 generally 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 aperture
1434 may be formed by another process, such as by way of a
non-limiting example, it may be drilled or the like.
[0176] In some embodiments, a removed portion 1541 may include a
generally backward S-shape with a hole formed in a generally
tubular member 1540 as shown in FIG. 74. The removed portion 1541
may be of any appropriate shape and size and the present teachings
are not limited to such.
[0177] A hitch ball mount 1600 may be formed as a monolithic unit
or otherwise may be integrally formed. The hitch ball mount 1600
may include a hitch receiver attachment portion 1614, a drop
portion 1618 and a hitch ball mount portion or tongue 1622, as
shown in FIGS. 75-76. The hitch receiver attachment portion 1614
may include a tubular portion 1626. The tubular portion 1626 may 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 portion 1626 may be of a
generally rectangular shape. The tubular portion 1626 may include a
pair of transverse apertures 1630 located on at least two sides
1634 of the tubular portion 1626. The tubular portion 1626 may
further include a generally angled end portion 1635. The angled end
portion 1635 may make it easier to load the tubular portion 1626
into mating engagement with the applicable hitch receiver.
[0178] The drop portion 1618 of the hitch ball mount 1600 may
extend generally between the hitch receiver attachment portion 1614
and the tongue 1622. The drop portion 1618 may be of any
appropriate distance. In some embodiments, the drop portion 1618
may be a zero drop. The appropriate distance of the drop portion
1618 may be based upon the distance the tongue 1622 may be desired
to extend from the hitch receiver attachment portion 1614 to
account for the use of the hitch ball mount 1600.
[0179] The tongue 1622 may extend from the drop portion 1618. The
tongue 1622 may include a hitch ball aperture 1644 positioned on
the upper surface 1640 of the tongue 1622 and may extend through
the tongue 1622. The hitch ball aperture 1644 may be shaped and
sized to receive a hitch ball in any appropriate manner.
[0180] A hitch ball mount 1700 may be formed as a monolithic unit
or otherwise may be integrally formed. The hitch ball mount 1700
may include a hitch receiver attachment portion 1714, a drop
portion 1718 and a hitch ball mount portion or tongue 1722, as
shown in FIGS. 77-78. The hitch receiver attachment portion 1714
may include a tubular portion 1726. The tubular portion 1726 may 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 portion 1726 may be of a
generally rectangular shape. The tubular portion 1726 may include a
pair of transverse apertures 1730 located on at least two sides
1734 of the tubular portion 1726. The tubular portion 1726 may
further include a generally angled end portion 1735. The angled end
portion 1735 may make it easier to load the tubular portion 1726
into mating engagement with the applicable hitch receiver.
[0181] The drop portion 1718 of the hitch ball mount 1700 may
extend generally between the hitch receiver attachment portion 1714
and the tongue 1722. The drop portion 1718 may be of any
appropriate distance. In some embodiments, the drop portion 1718
may be a zero drop. The appropriate distance of the drop portion
1718 may be based upon the distance the tongue 1722 may be desired
to extend from the hitch receiver attachment portion 1714 to
account for the use of the hitch ball mount 1700.
[0182] The tongue 1722 may extend from the drop portion 1718. The
tongue 1722 may include a hitch ball aperture 1744 positioned on
the upper surface 1740 of the tongue 1722 and may extend through
the tongue 1722. The hitch ball aperture 1744 may be shaped and
sized to receive a hitch ball in any appropriate manner.
[0183] 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 mounts
1100, 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 mounts 1100, 1200. Hydraulic fluid may be used with the
bladder to form the appropriate the hitch ball mounts 1100, 1200.
Hydro-forming may be used to generally avoid contact points and to
spread out the stress over substantially all of the hitch ball
mounts 1100, 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.
[0184] 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.
* * * * *