Abstract: A method of forming a vehicle component, particularly an elongated impact beam, having an open section structure, in a manner to provide predetermined strategically strengthened portions, comprising the steps of cold forming unhardened steel into a workpiece having mounting surfaces, selectively fixturing the mounting surfaces, static induction heating the workpiece with lengthwise surface eddy currents on selected portions, followed by quenching of the fixtured heated workpiece to form strengthened portions, and unfixturing the resulting component. Also disclosed is apparatus to accomplish this, and the resulting novel vehicle component.

Abstract: A structural door beam for vehicles includes an elongate open channel with an open section configuration defined by a central web and at least one side flange. A mounting tab projects outwardly from a side edge of the side flange and has a marginal edge surrounding a generally planar mounting surface configured to support a vehicle motion sensor. An integral reinforcing flange extends along portions of the side flange edge and the mounting tab edge and protrudes laterally at a predetermined angle to define an integral buttress which stiffens the mounting tab to avoid inadvertent activation of the vehicle motion sensor. An integral bead may also be provided to reinforce the mounting tab.

Abstract: An energy absorption impact system for vehicle bumpers and the like includes a mounting plate with a central opening therethrough, and a generally box-shaped sheet metal crush member. The crush member has a top wall, a bottom wall and opposite sidewalls arranged in a generally frustro-pyramidal shape, defining a large end connected with a vehicle bumper, and a small end connected with the mounting plate about the central opening. Impact on the vehicle bumper inelastically deforms the walls of the crush member toward the central opening in the mounting plate to absorb energy associated with the impact.

Abstract: A method of forming a vehicle component, particularly an elongated impact beam, having an open section structure, in a manner to provide predetermined strategically strengthened portions, comprising the steps of cold forming unhardened steel into a workpiece having mounting surfaces, selectively fixturing the mounting surfaces, static induction heating the workpiece with lengthwise surface eddy currents on selected portions, followed by quenching of the fixtured heated workpiece to form strengthened portions, and unfixturing the resulting component. Also disclosed is apparatus to accomplish this, and the resulting novel vehicle component.

Abstract: A method of forming a vehicle component, particularly an elongated impact beam, having an open section structure, in a manner to provide predetermined strategically strengthened portions, comprising the steps of cold forming unhardened steel into a workpiece having mounting surfaces, selectively fixturing the mounting surfaces, static induction heating the workpiece with lengthwise surface eddy currents on selected portions, followed by quenching of the fixtured heated workpiece to form strengthened portions, and unfixturing the resulting component. Also disclosed is apparatus to accomplish this, and the resulting novel vehicle component.