Abstract: A galvanized reinforcement beam is continuously formed by uncoiling a roll of galvanized sheet stock in a generally horizontal plane. Protrusions are formed at an upper surface of the sheet stock, which is then roll formed to form a tubular shape with the protrusions abutting a surface of the sheet stock to form venting gaps. The sheet stock is laser welded at the protrusions to continuously form a weld joint, where zinc oxide gas generated from the welding is permitted to escape an interior of the tubular shape through the venting gaps.

Abstract: A battery support structure for a vehicle includes a first peripheral member configured to be supported by a longitudinal section of a vehicle frame. A second peripheral member has an end surface that selectively attaches at an inside surface of the first peripheral member to enclose a corner section of a battery containment area. Prior to fixed attachment of the first and second peripheral members, a slip plane is defined between the end surface and the inside surface to adjust the second peripheral member along the first peripheral member to a predefined dimension of the battery containment area.

Abstract: A beam article for a vehicle includes a plurality of separate elongated metal sheets attached together to form generally planar walls of an elongated tubular structure. At least one of the plurality of separate elongated metal sheets has a shear wall that is disposed along a hollow interior of the elongated tubular structure and is attached at opposing walls of the elongated tubular structure. At least one of the plurality of separate elongated metal sheets comprises an edge that abuts a side surface of an adjacent one of the plurality of separate elongated metal sheets to define a non-radiused perpendicular weld corner along the elongated tubular structure.

Abstract: A battery support structure for a vehicle includes a first peripheral member configured to be supported by a longitudinal section of a vehicle frame. A second peripheral member has an end surface that selectively attaches at an inside surface of the first peripheral member to enclose a corner section of a battery containment area. Prior to fixed attachment of the first and second peripheral members, a slip plane is defined between the end surface and the inside surface to adjust the second peripheral member along the first peripheral member to a predefined dimension of the battery containment area.

Abstract: A bumper reinforcement beam includes sheets pre-formed to have integral features and to have a final beam shape with non-radiused corners and optimal impact properties, including beams with constant or varied cross-sectional shapes, and beams made of steel, aluminum, or hybrid materials or combinations of material, all of which allow minimization of weight. The non-radiused corners offer excellent impact strength and properties. Beam impact properties can be improved or locally tuned for particular functional requirements by material selection, or by adding an internal reinforcement on an inside center of the front wall, or by localized annealing of the welds to minimize stress risers, or by localized features and shapes. The sheets can be welded using welding processes that provide low heat-affected-zones around the weld or by localized annealing, thus minimizing any adverse effect of welding.

Abstract: A beam article for a vehicle includes a plurality of separate elongated metal sheets attached together to form generally planar walls of an elongated tubular structure. At least one of the plurality of separate elongated metal sheets has a shear wall that is disposed along a hollow interior of the elongated tubular structure and is attached at opposing walls of the elongated tubular structure. At least one of the plurality of separate elongated metal sheets comprises an edge that abuts a side surface of an adjacent one of the plurality of separate elongated metal sheets to define a non-radiused perpendicular weld corner along the elongated tubular structure.

Abstract: The present bumper impact beam includes pultruding polymer (e.g. thermoset polymer, preferably polyurethane) into continuous reinforcement (preferably carbon fibers or glass fibers), the reinforcement including fabrics selectively positioned and extending around corners for improved impact strength. The beam preferably has a 50%-70% fiber volume fraction that is relatively uniform throughout the part. A curved cooling support and/or beam design may be used to cause the cooled beam to have a sweep.

Abstract: A bumper reinforcement beam includes sheets pre-formed to have integral features and to have a final beam shape with non-radiused corners and optimal impact properties, including beams with constant or varied cross-sectional shapes, and beams made of steel, aluminum, or hybrid materials or combinations of material, all of which allow minimization of weight. The non-radiused corners offer excellent impact strength and properties. Beam impact properties can be improved or locally tuned for particular functional requirements by material selection, or by adding an internal reinforcement on an inside center of the front wall, or by localized annealing of the welds to minimize stress risers, or by localized features and shapes. The sheets can be welded using welding processes that provide low heat-affected-zones around the weld or by localized annealing, thus minimizing any adverse effect of welding.

Abstract: A multi-sheet beam includes sheets pre-shaped and/or pre-formed to have integral features and to cause a final beam shape with non-radiused corners and optimal impact properties when assembled, including beams with constant or varied cross sectional shapes. The non-radiused corners offer excellent impact strength over radiused corners. The sheets are selected to have desired (different) thicknesses and material properties for optimal impact results and low beam weight. To assemble, the sheets are fixtured together and welded to form box beam, such as a two-tube monoleg beam, preferably using welding processes having low heat-affected-zones around the weld. The multiple sheets can include grades of aluminum with high tensile strength well above extrudable grades of aluminum. Alternatively, the multiple sheets can be any grade of steel, such as high strength and ultra high strength steels. The fixturing and assembly technique minimizes capital expense on extruding machines and/or roll forming machines.

Abstract: The present bumper impact beam includes pultruding polymer (e.g. thermoset polymer, preferably polyurethane) into continuous reinforcement (preferably carbon fibers or glass fibers), the reinforcement including fabrics selectively positioned and extending around corners for improved impact strength. The beam preferably has a 50%-70% fiber volume fraction that is relatively uniform throughout the part. A curved cooling support and/or beam design may be used to cause the cooled beam to have a sweep.

Abstract: A hybrid impact beam, suitable for use as a reinforced impact beam in vehicle bumpers, includes an extruded aluminum section, a fiber reinforced polymeric (FRP) section, and a structural adhesive bonding them together. The components are arranged so that during an impact, the aluminum section experiences compression and receives the direct impact, the FRP section experiences tension, and the adhesive experiences minimal stress by being on a neutral plane of the beam's bending moment. The extruded aluminum beam is preferably extruded as an open section, but becomes a closed section when the polymeric section is attached. The FRP section is preferably a continuous carbon fiber reinforced polymeric section, although different reinforcements can be used. A related method includes bonding an extruded aluminum and fiber-reinforced polymeric section together to form a closed bumper impact beam.

Abstract: A multi-sheet beam includes sheets pre-shaped and/or pre-formed to have integral features and to cause a final beam shape with non-radiused corners and optimal impact properties when assembled, including beams with constant or varied cross sectional shapes. The non-radiused corners offer excellent impact strength over radiused corners. The sheets are selected to have desired (different) thicknesses and material properties for optimal impact results and low beam weight. To assemble, the sheets are fixtured together and welded to form box beam, such as a two-tube monoleg beam, preferably using welding processes having low heat-affected-zones around the weld. The multiple sheets can include grades of aluminum with high tensile strength well above extrudable grades of aluminum. Alternatively, the multiple sheets can be any grade of steel, such as high strength and ultra high strength steels. The fixturing and assembly technique minimizes capital expense on extruding machines and/or roll forming machines.