Abstract: A structural beam, particularly for use as a door pillar or a bumper of a motor vehicle, includes a one-piece elongated extruded member formed of a light metal. The member has therethrough an elongated, laterally enclosed cavity defined by elongated side walls including at least two generally parallel side walls. A deformation pressure is applied to walls extending generally transverse to the two side walls, with the result that there occurs controlled folding of the two side walls with the formation therein of folds that extend parallel to the direction of elongation of the member. Thus, the cross-sectional area of the cavity through the member is reduced.

Abstract: A beam for reinforcement of a vehicle body is extruded as a hollow shape having substantially planar parallel longitudinally extending deformation walls each of which is of variable wall thickness along its length. Two laterally extending grooves define a deformation zone having a maximal wall thickness allowing for a controlled folding of the shape.

Abstract: An energy absorbing structure is employed in a front or rear portion of a vehicle body. The structure is in the form of a unitary and one-piece longitudinally extending aluminum or aluminum alloy member that is extruded to have a substantially uniform cross section. The member is subjected to an aging heat treatment operation to impart a material strength to the member. Subsequently, at least one longitudinal zone of the member is subjected to an overaging heat treatment to thereby lower the material strength of such zone. As a result, by the member being subjected to longitudinally differential heat treatment, the member has material strengths differing longitudinal of the member. Upon an impact being imparted to the portion of the vehicle body, a force acting on the member will cause the zone thereof to be subjected to axial compression deformation.

Abstract: An intrusion beam for reinforcing a body panel of a vehicle and a vehicle door is formed by a unitary extruded elongated multichamber shape. The beam is longitudinally split from one end so that resulting individual internal chambers extend at acute angles in relation to the longitudinal axis of the beam. Connection between the intrusion beam and a door frame is provided by spot welding bimetallic strips to respective ends of the beam.

Abstract: Structural members are extruded with respective abutted edge portions having a transverse cross-sectional configuration complementarily shaped with locking tabs and undercut recesses. The tabs of a first member are interconnected by a unitary transversely extending and inwardly arcuate web. Such web is permanently deformed in a joining process by a deformation tool forcing the outwardly projecting tabs into locking engagement with the second member.

Abstract: A vehicle space frame comprising load bearing longitudinal structural members (2) formed from an integral extruded multicavity shape being split, reshaped and aligned to secondary complementary shaped members (8) is provided. A new method of joining the structural members is based on longitudinal internesting of complementary shaped outer surfaces of the members forming the supportive structure of the space frame.

Abstract: An integral manifold for a heat exchanger is formed from a hollow shape having a plurality of individual risers, initially having substantially solid cross-sections and subsequently reshaped by means of a reverse impact extrusion process into hollow risers. The walls of the hollow shape under the hollow risers are perforated, thus forming apertures constituting inlets connecting the cavity of the hollow shape with the individual hollow risers.

Abstract: An assembly for a motor vehicle heat exchanger includes a tubular member defined by a wall having inner and outer surfaces, an internal passage defined by the inner surfaces and an open end. An integral one-piece baffle is positioned within the internal passage at a selected position spaced from the open end. The baffle has an outer cross-sectional shape complementary to the internal cross-sectional shape of the tubular member. The baffle includes a bottom forming a closed first end closing the internal passage of the tubular member and a flange integral with the bottom and extending axially therefrom toward the open end of the tubular member, the flange forming a wall of the baffle. The baffle wall is expanded outwardly to result in permanent plastic outward deformation of the wall of the tubular member and thereby deform therein a circumferential indentation. The inner and outer surfaces of the wall of the tubular member are outwardly deformed permanently at the indentation.

Abstract: A manifold, especially a supply or receiving tank in a heat exchanger, is provided as an extruded/drawn tube with an outwardly and longitudinally extending protrusion part. Fastening flanges with a size larger than the width of the protrusion part are an integral portion of the protrusion part. The shaped tube with protrusion part is extruded or drawn, and then the protrusion part is perforated to form a plurality of apertures which are transformed in one or more steps by cold deformation into the fastening flanges of desired diameter, shape and length.

Abstract: A heat exchanger element includes a single and integrally extruded member having at least two hollow tubes having parallel longitudinal axes, each two adjacent hollow tubes being connected by at least two webs which extend parallel to the longitudinal axes and which are formed integrally with each of the two adjacent hollow tubes. The webs have therethrough plural perforations, and the material of each web between adjacent perforations therein is deflected to form a rib extending at an angle to the web. At least one tube has formed integrally therewith a projecting track which extends parallel to the longitudinal axes. Plural heat exchanger elements are connected at the respective tracks thereof to form a tube bundle.

Abstract: A method of manufacturing integrated manifolds for heat exchangers include providing hollow shape with a plurality of individual risers each having a substantially solid cross-section. Subsequently, the risers are reshaped by means of a reverse impact extrusion process into hollow risers. Finally, by perforating the wall of the hollow shape under the hollow risers, apertures are provided constituting inlets connecting the cavity of the hollow shape with the individual hollow risers.