Method for manufacturing a reinforced structural component, and article manufactured thereby

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.

1 . A method for manufacturing a reinforced structural component, said method comprising the steps of: 
 providing a body of sheet material;    carrying out a first forming operation on said body of sheet material so as to form an intermediate structural member which defines a channel extending along at least a portion of the length thereof;    providing a support member;    disposing said support member in said channel;    affixing said support member to said intermediate structural member so that it is retained in said channel; and    carrying out a second forming operation on said intermediate structural member having said support member retained therein, so as to at least partially enclose, and fixedly retain, said structural member within said channel.    
     
     
         2 . The method of  claim 1 , wherein at least one of said first forming operation and said second forming operation is a roll-forming operation.  
     
     
         3 . The method of  claim 1 , wherein said first forming operation and said second forming operation are both roll-forming operations.  
     
     
         4 . The method of  claim 1 , wherein said step of affixing said support member to said intermediate structural member comprises mechanically affixing said support member.  
     
     
         5 . The method of  claim 4 , wherein said step of mechanically affixing comprises affixing said support member by a mechanical structure selected from the group consisting of: a tab, a toggle, a piercing, a deformation, and combinations thereof.  
     
     
         6 . The method of  claim 1 , wherein said step of affixing said support member to said intermediate structural member comprises affixing said member through the use of: adhesive, a weld, a brazed joint, solder and combinations thereof.  
     
     
         7 . The method of  claim 1 , wherein the step of providing a support member comprises providing a roll-formed support member.  
     
     
         8 . The method of  claim 1 , wherein the step of providing a body of sheet material comprises providing an elongated web of sheet material.  
     
     
         9 . The method of  claim 1 , including the further step of cutting said intermediate structural member prior to the step of carrying out said second forming operation.  
     
     
         10 . The method of  claim 1 , including the further step of cutting said intermediate structural member after the step of carrying out said second forming operation.  
     
     
         11 . The method of  claim 1 , wherein said body of sheet material comprises steel.  
     
     
         12 . The method of  claim 1 , wherein said support member is fabricated from a material selected from the group consisting of ferrous metals, nonferrous metals, polymers, and combinations thereof.  
     
     
         13 . The method of  claim 1 , including the step of carrying out a further processing operation on said intermediate structural member.  
     
     
         14 . The method of  claim 13 , wherein said further processing operation is selected from the group consisting of: sweeping, bending, die forming, twisting, welding, cutting, drilling, crushing, heating, quenching, and combinations thereof.  
     
     
         15 . The method of  claim 13 , wherein said further processing operation is carried out before the support member is fixedly retained in said intermediate structural member.  
     
     
         16 . The method of  claim 13 , wherein said further processing operation is carried out after the support member is fixedly retained in said intermediate structural member.  
     
     
         17 . The method of  claim 16 , wherein said further processing operation is carried out after the implementation of said second forming operation.  
     
     
         18 . A reinforced structural member made according to the method of  claim 1.