Abstract: A method for forming a beam exhibiting non-parallel opposing surfaces including the steps of unreeling, in sheet form, a selected running length of a roll material and forming the steel roll into a generally three-dimensional and tubular shape exhibiting a closed cross section. Additional steps include heating the tubular shaped material inwardly displacing at least one of first and second opposing surfaces associated with the tubular shaped material, relative to one another, and concurrent with imparting an overall arcuate shape to the material.

Abstract: A reinforced structural component is manufactured by forming an intermediate structural member which defines a channel extending along at least a portion of its length. A support member is disposed in the channel and affixed to the intermediate structural member. A second forming operation is carried out on the combination of the intermediate structural member and support member so as to partially enclose and fixedly retain the support member therein. The method may be applied to metallic and nonmetallic structures, and may be utilized in conjunction with high speed metal forming processes such as roll forming. Disclosed herein are structures made according to the method as well as use of the method in the manufacture of structural components for motor vehicles.

Abstract: A structural member for the body of a motor vehicle includes a generally elongated support member which at least partially encloses an interior volume, and a reinforcing insert which is disposed in the interior volume. The reinforcing insert extends along at least a portion of the length of the support member, and has a cross section which defines a closed perimeter that encloses an area. The insert member may be configured so as to control its deformation characteristics thereby providing a structural member which efficiently and safely absorbs kinetic energy in a crash.

Abstract: A formed beam for use as a vehicle bumper having an elongated body exhibiting front and rear opposing surfaces and top and bottom surfaces interconnecting the front and rear surfaces, such that the beam defines a swept shape between first and second opposite ends. A plurality of spaced apart and transverse extending beads are formed upon the top extending surface of said beam and at least a portion of one of the front and rear surfaces are inwardly displaced relative to each other and during formation of an arcuate profile to the beam, and such that the front and rear surfaces exhibit at least partially non-parallel surfaces.

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.