Abstract: Multi-port tube structures are fabricated in a process in which a web of metallic material has a pattern of features formed therein by a rotary die forming process carried out on a continuous basis. The web of material is cut into strips which are folded so as to define a closed tubular structure having internal features defining longitudinal fluid flow channels.

Abstract: Multi-port tube structures are fabricated in a process in which a web of metallic material has a pattern of features formed therein by a rotary die forming process carried out on a continuous basis. The web of material is cut into strips which are folded so as to define a closed tubular structure having internal features defining longitudinal fluid flow channels.

Abstract: An improved vehicle box assembly with an upright front or side panel defined by a monolithic one-piece roll-formed steel sheet member having a desired three-dimensional configuration. The sheet steel member is roll-formed in the lengthwise direction thereof. The panel has a channel, preferably a closed tubular channel on the front panel, roll-formed along one edge of the sheet steel during forming of the panel. The closed tubular edge rail is preferably closed by a seam weld which extends lengthwise therealong and is performed in line with the roll-forming operation. The roll-formed panel is preferably provided with a flat shelf deformed horizontally to extend lengthwise along the panel downwardly from the top rail.

Abstract: A vehicle box assembly wherein a bed floor and the inner right and left side wall panels are defined by and assembled from two monolithic one-piece integrated side/floor panel members. The two panel members are preferably formed by roll forming a thin metal sheet so that only a single roll-formed panel configuration is required. Subsequent forming operations, such as punching or die forming, are carried out on the roll-formed configuration to create right and left panel members which are assembled to define the floor and opposed inner side panels of the box assembly.

Abstract: A structural assembly, such as for use as a rocker panel in an automotive vehicle and which includes an outer rocker cover and an inner attached and reinforcing member. The reinforcing member is constructed from a continuous steel grade and roll formed material and includes first and second spaced apart wall portions which converge at upper and lower extending ends. An integrally formed web interconnects the inner and outer portions at the lower extending end and exhibits a bulbous shaped configuration defined by an inner radius. Drainage holes are formed through bottommost facing locations of said web, at preselected distances along its length, and in order to evacuate water and paint.

Abstract: An improved vehicle box assembly with an upright front panel part and a horizontal floor panel part defined by a monolithic one-piece roll-formed steel sheet member having a desired three-dimensional configuration. The sheet steel member is roll-formed in the lengthwise direction thereof to define a plurality of parallel stiffening ribs. The roll-formed member is thereafter transversely bent to define both front and floor panel parts.

Abstract: An improved vehicle box assembly with an upright front or side panel defined by a monolithic one-piece roll-formed steel sheet member having a desired three-dimensional configuration. The sheet steel member is roll-formed in the lengthwise direction thereof. The panel has a channel, preferably a closed tubular channel on the front panel, roll-formed along one edge of the sheet steel during forming of the panel. The closed tubular edge rail is preferably closed by a seam weld which extends lengthwise therealong and is performed in line with the roll-forming operation. The roll-formed panel is preferably provided with a flat shelf deformed horizontally to extend lengthwise along the panel downwardly from the top rail.

Abstract: An improved vehicle box assembly with an upright front or side panel defined by a monolithic one-piece roll-formed steel sheet member having a desired three-dimensional configuration. The sheet steel member is roll-formed in the lengthwise direction thereof. The panel has a channel, preferably a closed tubular channel on the front panel, roll-formed along one edge of the sheet steel during forming of the panel. The closed tubular edge rail is preferably closed by a seam weld which extends lengthwise therealong and is performed in line with the roll-forming operation. The roll-formed panel is preferably provided with a flat shelf deformed horizontally to extend lengthwise along the panel downwardly from the top rail.

Abstract: A bed arrangement for a vehicle including a horizontally large floor member defined by a thin metal sheet having a plurality of raised stiffening ribs extending lengthwise thereof. The floor member has a cantilevered edge flange extending along a lengthwise side edge thereof, which edge flange protrudes downwardly below a bottom surface of the floor member. A hat-shaped cross rail is disposed transversely under said floor member, and has a pair of top flanges which supportingly engages the bottom surface of the floor member. The cross rail, where it crosses the edge flange, has a depression formed therein to provide clearance for the edge flange. The top flanges having flange sections which are deformed downwardly to define the profile of the depression while maintaining the continuity of the top flanges as they extend lengthwise of the cross rail.

Abstract: A vehicle structural beam, such as a door intrusion beam, which possesses an elongate tubular beam part which at opposite ends is provided with mounting flanges for securement to a vehicle frame. The elongate tubular beam part and the flanges provided at opposite ends are defined by an integral, one-piece, monolithic steel structure which has been initially roll-formed from an elongate flat metal sheet to define the closed tubular structure of the tubular beam part, and which has been subjected to heating and quenching so that the elongate tubular beam part is of relatively high strength steel throughout its entire length, whereas the integrally and monolithically joined end flanges remain as lower strength steel which has been significantly unaffected by the heat treatment and quenching so as to permit appropriate shaping thereof and ease of welding to the vehicle frame.

Abstract: A vehicle structural beam, such as a door intrusion beam, which possesses an elongate tubular beam part which at opposite ends is provided with mounting flanges for securement to a vehicle frame. The elongate tubular beam part and the flanges provided at opposite ends are defined by an integral, one-piece, monolithic steel structure which has been initially roll-formed from an elongate flat metal sheet to define the closed tubular structure of the tubular beam part, and which has been subjected to heating and quenching so that the elongate tubular beam part is of relatively high strength steel throughout its entire length, whereas the integrally and monolithically joined end flanges remain as lower strength steel which has been significantly unaffected by the heat treatment and quenching so as to permit appropriate shaping thereof and ease of welding to the vehicle frame.

Abstract: A vehicle structural beam, such as a door intrusion beam, which possesses an elongate tubular beam part which at opposite ends is provided with mounting flanges for securement to a vehicle frame. The elongate tubular beam part and the flanges provided at opposite ends are defined by an integral, one-piece, monolithic steel structure which has been initially roll-formed from an elongate flat metal sheet to define the closed tubular structure of the tubular beam part, and which has been subjected to heating and quenching so that the elongate tubular beam part is of relatively high strength steel throughout its entire length, whereas the integrally and monolithically joined end flanges remain as lower strength steel which has been significantly unaffected by the heat treatment and quenching so as to permit appropriate shaping thereof and ease of welding to the vehicle frame.