Gooseneck beam

Abstract

A beam having a gooseneck shape with two gooseneck portions. The beam may have a variety of cross sectional configurations. One such configuration has an upper front wall, a lower front wall, and an offset wall there between. The offset wall may be recessed, or offset away from the body of the beam. Also disclosed is a method of manufacturing the gooseneck beam by positioning a length of a material on a flat surface of a two-cam rotating member; gripping said material with said two-cam rotating member; restraining said length; rotating said two-cam rotating member to form a first and second; and pressing a portion of said material.

Description

BACKGROUND OF THE INVENTION

This invention relates to a gooseneck beam and a method to manufacture a gooseneck beam. Particularly, the present invention may be a bumper for motor vehicles.

Motor vehicle beams are used on motor vehicles to absorb impact and prevent damage to other, usually more costly, components of the motor vehicle. Due to the worldwide volume of motor vehicle usage, a decrease in the cost to produce a beam; a decrease in the weight of a single beam; or a decrease in the production time of a single beam, can be a significant savings in cost and resources.

Further, beams or bumpers that are mounted to motor vehicles generally require crash boxes and pole protectors. Crash boxes and pole protectors add cost, increase time of production, and increase weight to the motor vehicle on which the beam is placed.

As can be seen, there is a need for a motor vehicle beam or bumper that can be produced at a reduced cost, reduced production time, having a reduced weight. There is also a need for a motor vehicle beam that does not use crash boxes or pole protectors.

U.S. Patent Application Publication No. 2005/0104393 discloses a bumper reinforcement 2 having various cross sectional shapes (paragraph [0022]). This also discloses an aluminum bumper stay 4. This publication does not disclose a gooseneck beam shape. This publication does not disclose specific dimensions of the beam.

U.S. Patent Application Publication No. 2005/0067845 discloses a bumper and deformation element. This discloses an extruded aluminum bumper. This publication does not disclose a gooseneck beam shape. This publication does not disclose specific dimensions of the beam.

SUMMARY OF THE INVENTION

An aspect of the present invention is a gooseneck beam comprising a body; said body having a first beam portion that is oriented in a rear plane; said body having a second beam portion that is oriented in a front plane; a first gooseneck portion between said first beam portion and said second beam portion; said body having a third beam portion that is oriented in said rear plane; and a second gooseneck portion between said second beam portion and said third beam portion.

Another aspect of the present invention is a gooseneck beam, which comprises a body having a first beam portion, a third beam portion, and a second beam portion disposed between said first beam portion and said third beam portion; said second beam portion at least partially disposed in a front plane; a rear plane disposed rearwardly of said front plane; said first beam portion and said third beam portion each at least partially disposed in said rear plane; a first gooseneck portion disposed between said first beam portion and said second beam portion; and a second gooseneck portion disposed between said second beam portion and said third beam portion.

Yet another aspect is a method to form a gooseneck beam, comprising the steps of positioning a length of a material on a flat surface of a two-cam rotating member; gripping said material with said two-cam rotating member; restraining a length of said material; rotating said two-cam rotating member to form a first bend; and pressing of a punch to form a second bend of the gooseneck.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a pictorial view of an exemplary embodiment of a gooseneck beam of the present invention;

FIG. 2 is a top view of an exemplary embodiment of the gooseneck beam of the present invention;

FIG. 3 is a partial top view of an exemplary embodiment of the gooseneck beam of the present invention;

FIG. 4 is a cross sectional view of an exemplary embodiment of the present invention;

FIG. 5 is a second cross sectional view of an exemplary embodiment of the present invention;

FIG. 6 are schematic representations of various shapes of different exemplary embodiments of the gooseneck beam of the present invention;

FIGS. 7A, 7B, 7C, and 7D illustrate the comparisons of impact with regard to a prior art beam and the beam of the present invention;

FIG. 9 illustrates a method for creating the gooseneck beam of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is of the best currently contemplated modes of carrying out the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.

FIG. 1 illustrates an exemplary embodiment of the gooseneck beam, or beam 10 of the present invention. FIG. 2 illustrates an exemplary embodiment of the gooseneck beam 10 of the present invention. FIGS. 1 and 2 generally disclose the gooseneck shape of the beam 10. FIGS. 1 and 2 show a first and second gooseneck portion 12, 14, respectively. FIG. 3 illustrates a general cross section of an exemplary embodiment of a cross-section the gooseneck beam 10.

As illustrated in FIGS. 1 and 2, an exemplary embodiment of the present invention may have a first and second gooseneck portion 12, 14. Each gooseneck portion 12, 14 is generated about at least two radii; each separate radius may be positioned on opposite sides of the beam 10; and may be tangent to each other. For example, referring to FIG. 3, the front wall 60, 74 of the first gooseneck portion 12 may be generated about a first front wall radius 120 that is located forwardly of the beam 10 and a second or middle front wall radius 140 that is located rearwardly of the beam 10. The second or middle front wall radius 140 is located between the first front wall radius 120 and a third front wall radius 160 (seen in FIG. 2).

Referring to FIGS. 2 and 3, the rear wall 50 may be generated about a first rear wall radius 110, which radius 110 and corresponding origin or centerpoint is disposed forwardly of the beam 10, and a second (middle) rear wall radius 130, which is disposed rearwardly of the beam 10, and may be tangent to radius 110. The second (middle) rear wall radius 130 is located between the first rear wall radius 110 and a third rear wall radius 150, which may be tangent to said second rear wall radius 130.

In this description, forwardly refers to a location in front of the beam 10. It is understood that the beam 10 may be secured to a motor vehicle with the rear wall 50 facing the motor vehicle, and the front walls 60, 74 disposed in front, or forwardly of the rear wall 50. However it is understood that the beam 10 may be positioned on a motor vehicle in a variety of locational relationships. For example the beam 10 may be positioned where the front walls 60, 74 face the motor vehicle, and the rear wall 50 is in front of the front walls 60, 74, relative to the motor vehicle.

Due to the thickness of the beam 10 that is defined by the distance from the front walls 60, 74 to the rear wall 50; the front walls 60, 74 and the rear wall 50 may have different radii at any given gooseneck portion 12, 14. As illustrated in FIGS. 2 and 3, four (4) radii comprise a single gooseneck portion 12, or 14. For example a first front wall radius 120 may be about 700 mm, and a first rear wall radius 110 may be about 800 mm for any single gooseneck portion 12, 14. A middle or second front wall radius 140 may be about 800 mm, and a middle or second rear wall radius 130 may be about 700 mm. As illustrated in FIG. 3, the first front wall radius 120 and the first rear wall radius 110 are both disposed forwardly of the beam 10, and both 120, 110 may have the same center point or point of origin (not shown). Alternatively, the center points of radii 120, 110 may not coincide.

As further illustrated in FIG. 3, the second front wall radius 140 and second rear wall radius 130 may be disposed rearwardly of the beam 10, and both radii 140, 130 may have the same point of origin or center point. Alternatively, the center points of radii 140, 130 may not coincide.

As illustrated in FIG. 2, a third front wall radius 160 and third rear wall radius 150 may be disposed forwardly of the beam, similar to the first front wall radius 120 and a first rear wall radius 110. In one exemplary embodiment the first front wall radius 120, the second front wall radius 140, and the third front wall radius 160 have the same distance. In one exemplary embodiment the first rear wall radius 110, the second rear wall radius 130, and the third rear wall radius 150 have the same distance. In one exemplary embodiment, the first front wall radius 120 and the first rear wall radius 110 share the same point of origin, which is the same distance from the point of origin of the second front wall radius 140 and second rear wall radius 130, as the third front wall radius 160 and third rear wall radius.

The dimensions of the gooseneck beam 10 may vary. For example the beam 10 may be a variety of lengths to accommodate for the variety in motor vehicle widths. Also, the radii may be varied depending on the beam depth, which may be defined by the distance between the front plane 400 and the rear plane 410. The distance between the front plane 400 and the rear plane 410 may vary. For example if a beam 10 having a greater depth is desired, the gooseneck beam 10 may be designed with comparatively lower radii 110, 120, 130, 140, 150, 160.

The gooseneck beam 10 can be comprised of a variety of cross sectional shapes and configurations, such as illustrated in FIGS. 4 and 5, and the variety of cross sectional shapes illustrated in FIG. 6. FIG. 6 illustrates schematics of ten (10) other types of cross sections of the present invention. The vertical line disposed on the right of the schematic cross section designates the beam 10 front face.

FIG. 4 illustrates a cross sectional view of an exemplary embodiment of a gooseneck beam, or beam 10 of the present invention. This configuration may be referred to as a B-shaped configuration. In this exemplary embodiment, the beam 10 has a body 20. The body 20 has a top wall 30 having a top wall rear portion 32 and a top wall front portion 34. A rear wall 50 extends downwardly from the top wall rear portion 32 to a bottom wall 40. The bottom wall 40 extends forwardly to a lower front wall 60. The lower front wall 60 extends upwardly from said bottom wall 40. The lower front wall 60 extends upwardly to a lower horizontally oriented transverse wall 62. In the exemplary embodiment as illustrated in FIG. 3, the lower horizontally oriented transverse wall 62 extends inwardly and slightly upwardly (or toward the rear wall 50), to a vertically oriented recessed wall, also referred to an a vertical recessed wall 70. The vertical recessed wall 70 extending upwardly to an upper horizontally oriented transverse wall 72. The upper horizontally oriented transverse wall 72 extending outwardly and slightly upwardly (or away from the rear wall 50) to an upper front wall 74, said upper front wall 74 may be oriented in a substantially vertical plane. The upper front wall 74 extending upwardly to the top wall front portion 34. A rib 80 extending rearwardly from a vertical recess wall inside surface 71, to a rear wall inside surface 52.

FIG. 4 also illustrates one exemplary embodiment where the top wall front portion 34 may have a material thickness greater than that of the top wall rear portion 32. A rib front portion 82 may have a greater material thickness than a rib middle portion 84. A rib rear portion 86 may have a material thickness that is greater than that of the rib middle portion 84, and that is less than that of the rib front portion 82.

Also illustrated in FIG. 3 is an exemplary embodiment whereby a bottom wall front portion 44 may have a material thickness that is greater than that of a bottom wall rear portion 42.

In one exemplary embodiment the top and bottom walls 30, 40 have a thickness of about 3.5 mm near the front walls 74, 60, and the top and bottom walls 30, 40 have a thickness of about 2.2 mm near the rear wall 50. In one exemplary embodiment the rib front portion is about 3.5 mm thick, the rib middle portion 84 is about 2.2 mm thick, and the rib rear portion 86 is about 2.8 mm thick. In one exemplary embodiment the front walls 74, 60 are about 4.5 mm thick. In one exemplary embodiment the horizontal transverse walls 62, 72 are about 4.5 mm thick, and the vertical recessed wall 70 is about 5.5 mm thick. The rib 80 may connect to the vertical recessed wall inside surface 71 at a junction where the rib front portion is about 3.5 mm and the vertical recessed wall 70 is about 5.5 mm in thickness. In one exemplary embodiment the rib rear portion 86 may connect to the rear wall 50 at a junction where the rear rib portion 86 is about 2.8 mm and the rear wall 50 is about 4.2 mm thick. In one exemplary embodiment the front walls 60, 74 are disposed from the rear wall 50 by a distance of about 100.35 mm, which also defines the depth of the beam 10, and the depth of the top wall 30 and the bottom wall. In one exemplary embodiment the top wall 30 is disposed from the bottom wall 40 by a distance of about 110.5 mm, which represents the height of the beam 10. In one exemplary embodiment, the lower front wall 60, the vertical recessed wall 70, and the upper front wall 74 each comprise about ⅓ of the beam 10 height. In other word, each the lower front wall 60, the vertical recessed wall 70, and the upper front wall 74 are each about the same length.

FIG. 5 illustrates another cross sectional configuration of the present invention, having a substantially rectangular shell 500 having a rectangular shell rib 510 extending from a rectangular shell front wall 520 to a rectangular shell rear wall 530, to define two hollow chambers above and below the rectangular shell rib 510.

As illustrated in FIG. 6, the schematic of cross sectional configurations illustrated in FIGS. 6A, 6E, 6F, 6G, 6H, 6I, and 6J have the general configuration as described above with reference to FIG. 3, also referred to as the B-shaped configuration. Thus all of the illustrated, except for 6B, 6C, 6D have the configuration described with reference to FIG. 3. In other words, all except for 6B, 6C, and 6D may have a similar relationship with respect to the top wall 30, the bottom wall 40, the rear wall 50, the upper front wall 74, the lower front wall 60 and the vertical recessed wall 70. For example, 6E is representative of the cross sectional configuration of FIG. 3. FIG. 6F also comprises the representative cross sectional configuration of FIG. 3, with the additional component of a substantially vertically oriented panel 210.

The present invention is not limited to the cross sectional configuration as illustrated in FIG. 3. For example, as illustrated in FIG. 6B, the present invention may comprise a forwardly offset wall 200 instead of a vertical recessed wall 70 (of FIG. 4). And FIG. 6D is essentially FIG. 6B with a reversing of the front wall and rear wall. FIG. 6C is a cross sectional configuration of the present invention having a single front wall 220, a divider rib 230, and the outer housing 240.

FIGS. 7A, 7B, 7C, and 7D generally illustrate the difference in beam impact of the present invention when compared to a prior art beam. FIGS. 7A and 7B illustrate the prior art. FIGS. 7C and 7D illustrate the present invention. Specifically, the when encountering an equal force the prior art beam 1 sustains axial deformation at the location where the prior art beam 1 adjoins the pole or crash box 2. The present invention beam 10 absorbs the force near the point of impact 430 rather than distributing the force to a rail bracket 420.

The beam 10 may be attached to a motor vehicle by being bolted or welded to two brackets, one on each end of the beam 10.

This gooseneck beam 10 may have additional applications beyond motor vehicle bumpers, such as guardrails or other structures that are subject to impact.

In one exemplary embodiment the beam 20 may be comprised of aluminum. However other materials that can form a rigid structure can also be used, such as steel, composites, or wood. In one exemplary embodiment, the beam 10 may be formed from aluminum alloy 6005 T6 or 7108.70 T79. A non-linear stress-strain curve is used for this aluminum alloy.

An aluminum gooseneck beam 10 of the present invention may be formed with the extrusion process—and cooling table—that displaces a billet of aluminum through a stationary die. The aluminum displaced through the die may form the cross sectional shape of FIGS. 3, 4, or 6. When a particular mass of billet material is extruded through the die, a 50-100 foot long structural member may be formed. The structural member is then partitioned into smaller lengths for particular applications. The structural members are also washed.

Further, the gooseneck portions 12, 14, may be formed by a press bending process or a stretch forming process. The press bending process requires positioning the cut length of extruded material in a die cavity that has a desired gooseneck profile shape that the structural member is to take when the forming process is complete. Next and engaging process is used in which other structural tooling engages the ends of the cut length to restrain the structural member to prevent the walls from deforming for some distance from the ends of the member. Then pressing via a punch press, which may be located above the die cavity to push the cut length into the die cavity to form the shape of the structural member. The factor of springback is incorporated in the die cavity design. Springback occurs when the punch press is backed away from the die cavity. Further machining operations may occur in the forming cell or in subsequent operations to compete the final processing of the cut length. These may include bolt hole creation, saw cuts on the ends of the structural member, or bracket attachment.

The stretch forming process may also be used to form the gooseneck beam 10. Here, the cut length of the extruded material is positioned on flat surfaces of a two cam, rotating block structure. These rotating block structure have ends with gripping members capable of restraining the cut length to prevent the tube wall from deforming for some distance from the ends of the cut length as the blocks begin to rotate about their respective pivot positions. When the rotating blocks reach the end of rotation, a press action forms the secondary bend of the gooseneck. The rotating block structures must also account for springback. Thus the rotating blocks are designed to rotate beyond a desired rotation angle. The pivot points of the rotating blocks are selected to prevent the structural member walls from buckling and to minimize tube wall strain. Without proper positioning, buckling may occur at an inside radius of a gooseneck portion. The inside radius being the wall that is closer to the radius point of origin. Further machining operations may be used such as bolt hole creation, saw cut on the ends of the structural members, or bracket attachment.

FIG. 9 illustrates an exemplary process 700 to form the gooseneck beam of the present invention. Generally, the process or method 700 includes the steps of positioning 710 a length of a material on a flat surface of a two-cam rotating member. Then gripping 720 said material with said two-cam rotating member. Third, restraining 730 a length of said material. Fourth, rotating 740 said two-cam rotating member to form a first bend; and then pressing 750 of a punch to form a second bend of the gooseneck.

It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.

Claims

1. A gooseneck beam comprising:

a body;

said body having a first beam portion that is oriented in a rear plane;

said body having a second beam portion that is oriented in a front plane;

a first gooseneck portion between said first beam portion and said second beam portion;

said body having a third beam portion that is oriented in said rear plane; and

a second gooseneck portion between said second beam portion and said third beam portion.

2. The gooseneck beam of claim 1, wherein said rear plane is substantially parallel with said front plane.

3. The gooseneck beam of claim 1, wherein said body has a substantially rectangular cross sectional configuration.

4. The gooseneck beam of claim 1, wherein said body comprises a B-shaped cross sectional configuration.

5. The gooseneck beam of claim 1, wherein said body is formed from aluminum.

6. The gooseneck beam of claim 1, wherein said first gooseneck portion is generated about a first rear wall radius, a first front wall radius, a second rear wall radius, and a second front wall radius.

7. The gooseneck beam of claim 1, wherein said second gooseneck portion is generated about a second rear wall radius, a second front wall radius, a third rear wall radius and a third front wall radius.

8. The gooseneck beam of claim 1, wherein said body is capable of being secured to a motor vehicle.

9. The gooseneck beam of claim 1, wherein said body is formed from a process that comprises the steps of:

positioning a length of a material on a flat surface of a two-cam rotating member;

gripping said material with said two-cam rotating member;

restraining a length of said material;

rotating said two-cam rotating member to form a first bend; and

pressing of a punch to form a second bend of the gooseneck.

10. The gooseneck beam of claim 1, wherein said body is formed from a process that comprises the steps of:

positioning extruded material on flat surfaces of a two cam, rotating block structure;

restraining a cut length of said extruded material to prevent the tube wall from deforming for some distance from the ends of the cut length as the blocks begin to rotate about respective pivot positions;

pressing the desired gooseneck portion of said cut length to form a gooseneck portion; and

machining operations to form bolt hole creation or means for bracket attachment.

11. A gooseneck beam, which comprises:

a first beam portion, a third beam portion, and a second beam portion disposed between said first beam portion and said third beam portion;

said second beam portion at least partially disposed in a front plane;

a rear plane disposed rearwardly of said front plane;

said first beam portion and said third beam portion each at least partially disposed in said rear plane;

a first gooseneck portion disposed between said first beam portion and said second beam portion; and

a second gooseneck portion disposed between said second beam portion and said third beam portion.

12. The gooseneck beam of claim 11, wherein said rear plane is substantially parallel with said front plane.

13. The gooseneck beam of claim 11, wherein said body has a substantially rectangular cross sectional configuration.

14. The gooseneck beam of claim 11, wherein said body comprises a B-shaped cross sectional configuration.

15. The gooseneck beam of claim 11, wherein said body is formed from aluminum.

16. The gooseneck beam of claim 1, wherein said first gooseneck portion is generated about a first rear wall radius, a first front wall radius, a second rear wall radius, and a second front wall radius.

17. The gooseneck beam of claim 11, wherein said second gooseneck portion is generated about a second rear wall radius, a second front wall radius, a third rear wall radius and a third front wall radius.

18. The gooseneck beam of claim 11, wherein said body is capable of being secured to a motor vehicle.

19. The gooseneck beam of claim 11, wherein said body is formed from a process comprising the steps of:

positioning a length of a material on a flat surface of a two-cam rotating member;

gripping said material with said two-cam rotating member;

restraining a length of said material;

rotating said two-cam rotating member to form a first bend; and

pressing of a punch to form a second bend of the gooseneck.

20. The gooseneck beam of claim 11, wherein said body (20) is formed from a stretch forming process comprising the steps of:

positioning extruded material on flat surfaces of a two cam, rotating block structure;

restraining a cut length of said extruded material to prevent the tube wall from deforming for some distance from the ends of the cut length as the blocks begin to rotate about respective pivot positions;

pressing the desired gooseneck portion of said cut length to form a gooseneck portion; and

machining operations to form bolt hole creation or means for bracket attachment.

21. A method to form a gooseneck beam, comprising the steps of:

positioning a length of a material on a flat surface of a two-cam rotating member;

gripping said material with said two-cam rotating member;

restraining a length of said material;

rotating said two-cam rotating member to form a first bend; and

pressing of a punch to form a second bend of the gooseneck.