Abstract: A stamped beam for a vehicle door with improved structural strength while minimizing added weight to the vehicle. The beam includes a corrugated beam body with integral end brackets for mounting the beam in the vehicle door. The beam body has a sinusoidal cross-sectional configuration with a longitudinal valley allowing the entire beam to be stamped from an integral metal blank forming the mounting brackets. For additional strength, a tubular center member is welded within the longitudinal valley. The tube acts as a tuning mechanism by altering the thickness of the tube wall according to the application of the beam.

Abstract: A process of manufacturing vehicle manifolds particularly for attaching the manifold tubes to the base plate which is used to secure the manifold to the engine block. The manifold assembly includes a plurality of manifold tubes having at least one end secured to the base plate. The tubes are secured to the plate in groups utilizing a pool of epoxy isolated along the base plate by a ridge. The liquified epoxy flows around the tubes to secure the tubes within the plate once the epoxy is cured and hardened.

Abstract: A process of hydroforming tubular suspension and frame components of a vehicle which results in substantial weight reductions while maintaining strength and integrity of the assembly. The process forms a hydroformed tubular trailing arm having a curved configuration to comply with the design requirements of the suspension. The trailing arm has a spring seat base hydroformed therein, an extruded shock mount and bushing mount formed as integral components. A mounting plate is attached to the trailing arm for attaching the vehicle wheel.

Abstract: A vehicle door intrusion beam having a hollow cross-sectional configuration with less weight, greater flexibility and improved impact resistance. The beam body is formed of a single piece of material by roll forming a tubular blank to the desired cross-sectional configuration. End brackets secured to or integrally formed with the beam body mount the beam to the door assembly while also facilitating absorption of impacts. Corrugations may be added to the end brackets for additional impact absorption. Various hollow cross-sectional configurations are contemplated for the beam body including a single-piece with a closed I-beam configuration.

Abstract: A gasket for a connection joint of a vehicle exhaust system to seal two sections of the system against leakage of exhaust. The gasket is an integral ring consisting of a main flange portion which is disposed between the connected sections of the exhaust system and a perpendicular radial flange which extends into the exhaust tube. The main flange includes a raised circumferential seal ridge. The radial flange includes a plurality of serrations which engage the interior of the exhaust section to retard rotation and removal of the gasket.

Abstract: A hydroforming process and apparatus for manufacturing components of a vehicle exhaust or intake manifold. The hydroforming process is utilized to form a tubular member to the desired configuration for use in a manifold. The tubular member is loaded into a hydroform press and filled with a suitable liquid. The liquid within the tube is pressurized in order to maintain a predetermined internal fluid pressure which prevents collapse and crimping of the tube during forming. The hydroform press includes two sets of dies to form a compound bend in the pressurized tube. Upper and lower dies close on the tube first to bend the tube in a vertical plane. Horizontal dies are wedged inwardly spreading the first die set and bending the tube in a horizontal plane. As a result, a compound configuration may be placed on the tube making it suitable for use in a vehicle manifold.

Abstract: A hydroforming process and apparatus for manufacturing components of a vehicle exhaust or intake manifold. The hydroforming process is utilized to form a tubular member to the desired configuration for use in a manifold. The tubular member is loaded into a hydroform press and filled with a suitable liquid. The liquid within the tube is pressurized in order to maintain a predetermined internal fluid pressure which prevents collapse and crimping of the tube during forming. The hydroform press includes two sets of dies to form a compound bend in the pressurized tube. Upper and lower dies close on the tube first to bend the tube in a vertical plane. Horizontal dies are wedged inwardly spreading the first die set and bending the tube in a horizontal plane. As a result, a compound configuration may be placed on the tube making it suitable for use in a vehicle manifold.