SHEET METAL ROCKER ARM WITH INTEGRALLY FORMED CROSS MEMBER
A sheet metal rocker arm of the end pivot rocker arm type formed by bending into a U shape a precursor sheet metal piece and characterized by having a reinforcing cross member which is integrally formed by bending a tab that is cut in the central portion of the connecting part of a U-channel element to yield a reinforcing cross member to provide a unitary structure that introduces substantially enhanced stiffness to the rocker arm. The method of creating integrally formed reinforcing cross-members by appropriately cutting slits that provide reinforcing members can be applied to any stamped rocker arm that has a U-channel architecture, e.g., including, for example, rocker arms for pushrod type valvetrains as well as roller finger follower type rocker arms. Provision of the integrally formed cross member abutting the inner wall of the sides of the U-shaped rocker arm renders stiffness to the rocker arm that enables an engine to operate at a higher rpm and thereby improves horsepower output.
This invention relates to an improved rocker arm formed from sheet metal and characterized by an integrally formed cross member which provides advantageous added stiffness to the rocker arm.
BACKGROUND OF THE INVENTIONGenerally, prior art rocker arms formed from sheet metal are bent to a U-shape and then provided with an opening in the center, flat section. The U-channel can be oriented up or down and is provided with an opening or “window” at the center, either for a pivot attachment or for mounting a roller assembly. The window is made by punching out the material and discarding the punched out portion.
These prior art rocker arms from sheet metal typically have a U-shaped lateral cross-section and have no reinforcing cross members between opposing sides. Under load these rocker arms deflect such that opposing sides move outward and their ends move upwards, resulting in a loss of longitudinal stiffness. Lack of stiffness in rocker arms detracts from efficiency especially when operating at high engine speeds. The buckling from the desired shape and insufficiency of rocker arm stiffness detract from the capability to achieve maximum engine power.
As disclosed in U.S. Pat. No. 7,185,618 a sheet metal rocker arm with reinforcing cross members is provided by bending tabs formed on a tube insert so that the tabs of the tube insert abut the sides a U shape rocker arm formed by bending a sheet metal precursor to form a U shape.
In the present invention as distinguished from that of U.S. Pat. No. 7,185,618 wherein the reinforcing cross members are provided by bending tabs on a tubular insert, introduced into the axle assembly holes, the reinforcing bent tubular cross members are integral to the sheet metal piece, i.e.,.are provided by bending a tab in the sheet metal piece itself from which the U shape rocker arm is shaped.
The present invention accordingly provides an economical and expeditious means for providing a sheet metal rocker arm possessing greater relative stiffness by an improved construction configuration.
SUMMARY OF THE INVENTIONThe invention provides an improved rocker arm of the roller finger follower type formed from sheet metal and characterized by having at least one cross member which is integrally formed within the rocker arm itself and which yields a unitary structure that provides substantial stiffness without adding additional weight to the rocker arm. The method of the invention can be applied to any stamped rocker arm that has a U-channel architecture, e.g., including, for example, rocker arms for pushrod type valvetrains as well as roller finger follower type rocker arms. Provision of the integrally formed cross member renders stiffness to the rocker arm, tends to prevent distortion and enables an engine to operate at a higher rpm and thereby to produce more horsepower.
In the rocker arm forming method of the invention, a flat patterned sheet metal piece is bent into a U-shape precursor. In creating the desired reinforcing cross-member, the U-shape precursor a tab or a multiplicity of tabs are formed by slitting the sheet meal precursor and subsequently to provide an opening or “window” while at the same time creating a reinforcing cross-member. This piercing of the sheet metal as in the present invention without punching out and removing the material is referred to as lancing. However, this is not intended to indicate that part of the sheet metal resulting by bending the slit portion may not be discarded to lessen the overall weight. The tab or tabs according to the method of the invention are properly sized and bent such that the side edges of the bent tabs contact the interior opposite sidewalls of the U-shaped precursor without interfering with the placement of the roller assembly. It should be noted that most rocker arms are shaped as to be narrower at each end than at the center where the window is contained. In the invention, the tab or tabs created by the slots that provide a cross-member is bent sufficiently so that side edges of the bent tab can be brazed, welded or otherwise secured to the interior side walls of the rocker arm.
The rocker arm of the invention is produced by the sheet metal stamping process. During a conventional sheet metal stamping process, openings are created in one or more surfaces by material removal, i.e., by punching out a “window.” In accordance to the method of the invention for making a roller finger follower rocker arm from sheet metal, essentially no material need be removed in forming the opening for the roller, except for material that may be required to provide die clearance or determine to be suitable to reduce the mass of the rocker arm. Instead, the opening is formed by making slits from which one or two bent tabs are created. Material at the slit portion instead is bent to create reinforcing cross-members connected to the interior sides of the rocker arm. An opening in a rocker arm that comprises a U-shaped slit where a single tab is formed, i.e., tab or an H-shaped slit comprising two tabs 52 and 54 in
The method of the invention is applicable to rocker arms used in overhead cam valvetrains described as end-pivot, center-pivot and in cam-in-block pushrod valvetrains as well as roller finger follower rocker arms. All other rocker arm types will benefit from the stiffness derived by the addition of formed-in-place cross members. Although only one type of roller finger follower rocker arm is illustrated and defined, the essence of the method of the invention for creating an integrally formed cross-member is applicable to all types in addition to the described welded and brazed roller finger follower rocker arm.
Referring in particular to the drawings,
As shown in
Although the invention has been described in terms of particular embodiments, one skilled in the art will recognize that various changes in the sequence of steps for lancing the sheet metal and securing the tab-formed cross-member piece and equipment applied in the operative method can be made based on the concept herein provided and such are meant to be included herein. Accordingly, the invention is only to be limited by the scope of the appended claims.
Claims
1. A method for manufacturing a sheet metal rocker arm having integrally reinforcing cross members and substantially enhanced relative structural integrity and stiffness comprising
- (a) bending a patterned sheet metal precursor blank to form a longitudinal U-channel with straight sides generally conforming to a rocker arm and a central portion connecting the sides and having dimensions; and
- (b) lancing a shaped opening comprising a tab in the central portion; and
- (c) bending the end of said tab inwardly into the U-channel to form a cross-member transverse to sides of the U-channel and such that side edges of said tab abut against the inner sidewalls of the U-channel sides; and
- (d) securing said tab side to the inner sidewalls of the U-channel to integrate said tab and said side members to produce a rigid structure.
2. The method of claim 1 wherein the shaped opening in the central portion comprises a U-shape to produce a single tab yielding a single cross-member between the U-channel sides.
3. The method of claim 1 wherein the slit generally comprises an H-shape to produce two tabs to yield a pair of cross-members between the U channel sides.
4. The method of claim 2 wherein the tab has one or more holes to reduce the total mass of the rocker arm.
5. The method of claim 3 wherein a portion of one or both tabs is discarded to reduce the total mass of the rocker arm.
6. A rocker arm formed by the method of claim 1.
7. A rocker arm formed by the method of claim 2.
8. A rocker arm formed by the method of claim 3.
9. A rocker arm formed by the method of claim 4.
10. A rocker arm formed by the method of claim 5.
Type: Application
Filed: Jul 28, 2008
Publication Date: Jan 28, 2010
Inventor: THOMAS C. EDELMAYER (Canton, MI)
Application Number: 12/180,593
International Classification: B21D 31/00 (20060101); B21D 28/00 (20060101);