Abstract: A bumper construction for vehicles constructed of a single strip of metal roll-formed into a completely enclosed tubular member in which a foamed-in-place material is located in and completely fills only a central section of the tubular member a relatively short distance on each side of the central axis of the vehicle. An apparatus is provided for manufacturing roll-formed bumpers partially filled with a foam-in-place material, the bumpers including material defining a continuous closed section defining an open interior and opposing open ends. The apparatus includes a turntable with a plurality of holders including arms shaped to extend partially into the bumpers, and a plug on the end of each arm configured to block off the open interior of the bumper. The holders are pivotally mounted on the turntable so that a bumper can be slipped onto a selected holder, pivoted to an upright position, and then rotated by the turntable under an injector for dispensing foamable reaction injectable urethane (RIM) material.

Abstract: A bumper construction for vehicles constructed of a single strip of metal roll-formed into a completely enclosed tubular member in which a foamed-in-place material is located in and completely fills only a central section of the tubular member a relatively short distance on each side of the central axis of the vehicle. An apparatus is provided for manufacturing roll-formed bumpers partially filled with a foam-in-place material, the bumpers including material defining a continuous closed section defining an open interior and opposing open ends. The apparatus includes a turntable with a plurality of holders including arms shaped to extend partially into the bumpers, and a plug on the end of each arm configured to block off the open interior of the bumper. The holders are pivotally mounted on the turntable so that a bumper can be slipped onto a selected holder, pivoted to an upright position, and then rotated by the turntable under an injector for dispensing foamable reaction injectable urethane (RIM) material.

Abstract: An end bumper for vehicles constructed from a single sheet of high-tensile strength steel roll-formed to provide two side-by-side tubular sections. Each section has a front wall, an outer side wall, a rear wall, and an inner side wall, the inner side walls being spaced one from the other and connected together by a web roll-formed integrally with the inner side walls. The front walls each have extended ends overlapping and abutting the web. The extreme ends of the front walls also form an abutting juncture which is welded together and also welded to the web. The bumper has a sweep formed by a sweep-forming mechanism having curvilinear external and internal mandrels conforming to the inner configuration and outer configuration of the bumper so as to provide a passageway therebetween for receiving the bumper. The bumper is passed through the passageway while the roll-forming of the bumper takes place upstream of the mandrels.

Abstract: An end bumper for vehicles constructed from a single sheet of high-tensile strength steel roll-formed to provide two side-by-side tubular sections. Each section has a front wall, an outer side wall, a rear wall, and an inner side wall, the inner side walls being spaced one from the other and connected together by a web roll-formed integrally with the inner side walls. The front walls each have extended ends overlapping and abutting the web. The extreme ends of the front walls also form an abutting juncture which is welded together and also welded to the web. The bumper has a sweep formed by a sweep-forming mechanism having curvilinear external and internal mandrels conforming to the inner configuration and outer configuration of the bumper so as to provide a passageway therebetween for receiving the bumper. The bumper is passed through the passageway while the roll-forming of the bumper takes place upstream of the mandrels.

Abstract: A rear step bumper is provided for a vehicle. The bumper is roll-formed into a tubular shape and includes a top wall, a bottom wall, an inner wall, and an outer wall, and further includes ends and an intermediate section. The outer wall is sheared from the top wall and the bottom wall in the intermediate section, and also sheared transversely so as to form opposing panels, which opposing panels are bent toward the inner wall into engagement with the inner wall and secured to the inner wall. The opposing panels reinforce the tubular member in the intermediate section to maintain the structural integrity of the bumper, and further are integrally formed from material in the tubular member to facilitate manufacture and reduce costs. The method of manufacture is also disclosed.

Abstract: A cutoff apparatus is adapted to be positioned adjacent a roll-forming machine, and is particularly adapted for adjustably receiving and cutting bumper-length segments from a swept elongated shape made of high strength steel being extended from the roll-forming machine. The cutoff apparatus includes a carriage with rollers for rollingly engaging the elongated shape to align the carriage with the elongated shape, the carriage being adapted to periodically move with the roll-formed shape for a short distance as the roll-formed shape is being formed. The cutoff apparatus further includes a blade operably mounted to the carriage for cutting segments from the roll-formed shape on the fly.

Abstract: A bumper bar for vehicles formed from rolled sheet steel having a closed tubular profile designed to have a high impact resistance, high strength-to-weight ratio, and a low cost of manufacture. The bar is preferably swept along its longitudinal axis to create a curvature consistent with modern automotive designs.

Abstract: A bumper bar for vehicles formed from rolled sheet steel having a closed tubular profile designed to have a high impact resistance, high strength-to-weight ratio, and a low cost of manufacture. The bar is preferably swept along its longitudinal axis to create a curvature consistent with modern automotive design.

Abstract: A bumper bar for vehicles formed from rolled sheet steel having a closed tubular profile designed to have a high impact resistance, high strength-to-weight ratio, and a low cost of manufacture. The bar is preferably swept along its longitudinal axis to create a curvature consistent with modern automotive designs.

Abstract: A roll-formed door beam is provided for a vehicle which has an elongated shaped including a hat shaped portion and one to two looping portions. The hat shaped portion includes an upper flat surface for attachment and downwardly extending sides. The looping portions includes a bottom flat surface for attachment and looping sides which loopingly extend backwardly toward the base of the hat shaped portion. The looping sides cooperate with the side of the hat portion to stabilize the beam during flexure thus increasing the strength to thickness ratio of the beam.