Abstract: A continuous process for producing a shaped metal member from a feedstock comprising a flat web of metal includes a roll-forming station for shaping the web, a cutting station for cutting the shaped web into individual members, and a processing station for altering a physical characteristic of the metal comprising the members. The processing may include heat treating and/or shaping. The process may also be operable to carry out further operations such as marking, inspection, sorting and the like. Also disclosed is an apparatus for carrying out the process.

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 system for delivering a coolant fluid to a workpiece has a reservoir for retaining the fluid, a pump for delivering fluid from the reservoir, a supply line in communication with the workpiece and a diverter valve. A bypass line is in communication with the diverter valve, and the valve may be utilized to deliver fluid from the reservoir to the workpiece or to bypass the workpiece and circulate fluid back to the reservoir. The system also includes a fluid return line for conveying fluid from the workpiece back to the reservoir.

Abstract: A frame system for a motor vehicle includes a plurality of frame members each having a connector socket defined therein. The system further includes a connector having an outer profile configured to engage the sockets of two of the frame members so as to connect them in a fixed angular relationship. The connectors are composite bodies including a core member and an exterior body which covers at least a portion of the core member and defines a portion of the outer profile of the connector. Also disclosed are frames which employ the system and methods for manufacturing the frames.

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: A frame system for a motor vehicle includes a plurality of frame members each having a connector socket defined therein. The system further includes a connector having an outer profile configured to engage the sockets of two of the frame members so as to connect them in a fixed angular relationship. The connectors are composite bodies including a core member and an exterior body which covers at least a portion of the core member and defines a portion of the outer profile of the connector. Also disclosed are frames which employ the system and methods for manufacturing the frames.

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: A system for delivering a coolant fluid to a workpiece has a reservoir for retaining the fluid, a pump for delivering fluid from the reservoir, a supply line in communication with the workpiece and a diverter valve. A bypass line is in communication with the diverter valve, and the valve may be utilized to deliver fluid from the reservoir to the workpiece or to bypass the workpiece and circulate fluid back to the reservoir. The system also includes a fluid return line for conveying fluid from the workpiece back to the reservoir.

Abstract: A continuous process for producing a shaped metal member from a feedstock comprising a flat web of metal includes a roll-forming station for shaping the web, a cutting station for cutting the shaped web into individual members, and a processing station for altering a physical characteristic of the metal comprising the members. The processing may include heat treating and/or shaping. The process may also be operable to carry out further operations such as marking, inspection, sorting and the like. Also disclosed is an apparatus for carrying out the process.

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: 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 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.