Bumper beam assembly and method

Abstract

The present invention relates to improved methods for manufacturing bumper beam assemblies and bumper beam assemblies made by such methods. One method of the invention allows bumper beams of different longitudinal configurations to be made by selecting open cross-sectioned, roll-formed bumper beam members from different sets of beam members and fixing them to bumper beam mounting structures. The mounting structures close off the open cross-section of the bumper beam members. Another method of the invention allows bumper beams for varying applications to be made by selecting bumper beam members from inventory and fixing them to a bumper beam mounting structure.

What is claimed is:  
     
         1 . A method for forming a plurality of bumper beam assemblies comprising: 
 roll forming from sheet metal a plurality of elongated bumper beam members having substantially identical cross-sectional configurations including one opened side, said plurality of bumper beam members including at least a first set of bumper beam members having a first longitudinal configuration and a second set of bumper beam members having a second longitudinal configuration different from said first longitudinal configuration,    providing a plurality of elongated, generally planar bumper beam mounting structures,    selecting a number of bumper beam members from one of said first and second sets of bumper beam members;    selecting a bumper beam mounting structure from said plurality of bumper beam mounting structures; and    fixing said selected number of bumper beam members on said selected mounting structure such that said selected mounting structure closes said one opened side of each of the selected number of bumper beam members.    
     
     
         2 . A method according to  claim 1 , wherein said selected number of bumper beam members are from said first set of bumper beam members, and wherein said first longitudinal configuration of the bumper beam members selected from said first set comprises a longitudinal curvature, said method further comprising: 
 bending said selected mounting structure to conform to the generally same longitudinal curvature of said selected number of bumper beam members from said first set.    
     
     
         3 . A method according to  claim 1 , wherein providing said plurality of elongated bumper beam mounting structures comprises stamping said plurality of bumper beam mounting structures from metal material.  
     
     
         4 . A method according to  claim 1 , wherein said stamping provides said bumper beam mounting structures with varying heights.  
     
     
         5 . A method according to  claim 1 , wherein said fixing is accomplished by welding.  
     
     
         6 . A method according to  claim 1 , wherein said selected mounting structure comprises a plurality of stamped metal sheets welded to one another.  
     
     
         7 . A method according to  claim 1 , wherein said selected mounting structure comprises a single sheet of stamped sheet metal.  
     
     
         8 . A method according to  claim 1 , wherein said first longitudinal configuration of said bumper beam members selected from said first set comprises a longitudinal curvature having an inside sweep and wherein said second longitudinal configuration of said bumper beam members selected from said second set comprises a longitudinal curvature having an outside sweep, said method further comprising: 
 bending said selected mounting structure to conform to the generally same longitudinal curvature of said selected number of bumper beam members from said one of said first and second sets of bumper beam members.    
     
     
         9 . A method for forming a plurality of bumper beam assemblies for accommodating different applications comprising: 
 roll forming from sheet metal a plurality of elongated bumper beam members having substantially identical longitudinal configurations and substantially identical cross-sectional configurations to form an inventory of elongated bumper beam members;    stamping from sheet metal a plurality of elongated bumper beam mounting structures;    selecting a first number of said bumper beam members from said inventory;    fixing said first number of bumper beam members to a selected one of said bumper beam mounting structures to form a first bumper beam assembly;    selecting a second number of bumper beam members different from said first number;    fixing said second number of bumper beam members to another selected one of said bumper beam mounting structures to form a second bumper beam assembly different from said first bumper beam assembly.    
     
     
         10 . A method according to  claim 9 , wherein said first number of bumper beam members is one, and wherein said second number of bumper beam members is two.  
     
     
         11 . A method according to  claim 9 , wherein said first number of bumper beam members comprises two bumper beam members mounted vertically with respect to one another on said selected one of said bumper beam mounting structures.  
     
     
         12 . A method according to  claim 9 , wherein said first number of bumper beam members comprises two bumper beam members nested within one another.  
     
     
         13 . A bumper beam assembly comprising: 
 a bumper beam mounting structure; and    a plurality of elongated bumper beam members fixed to said bumper beam mounting structure, said bumper beam members having substantially identical cross-sectional configurations having one open side,    said bumper beam mounting structure closing off said one open side of each of said bumper beam members.    
     
     
         14 . A bumper beam assembly according to  claim 13 , wherein said bumper beam members are mounted vertically with respect to one another on said bumper beam mounting structure.  
     
     
         15 . A bumper beam assembly according to  claim 13 , wherein said bumper beam members comprise two bumper beam members nested within one another.