Internally reinforced hydroformed assembly and method of making same

Abstract

An internally reinforced hydroformed assembly and method of making same includes a hydroformed tubular member and a reinforcement disposed within the hydroformed tubular member prior to hydroforming. The internally reinforced hydroformed assembly and method of making same also includes at least one weld to secure the reinforcement to an interior surface of the hydroformed tubular member.

1 . An internally reinforced hydroformed assembly comprising: 
 a hydroformed tubular member;    a reinforcement disposed within said hydroformed tubular member prior to hydroforming; and    at least one weld to secure said reinforcement to an interior surface of said hydroformed tubular member.    
     
     
         2 . An internally reinforced hydroformed assembly as set forth in  claim 1  wherein said reinforcement has a generally planar cross-sectional shape.  
     
     
         3 . An internally reinforced hydroformed assembly as set forth in  claim 1  wherein said reinforcement has a generally “L” cross-sectional shape.  
     
     
         4 . An internally reinforced hydroformed assembly as set forth in  claim 1  wherein said reinforcement has a generally “C” cross-sectional shape.  
     
     
         5 . An internally reinforced hydroformed assembly as set forth in  claim 1  wherein said reinforcement has a generally top hat cross-sectional shape.  
     
     
         6 . An internally reinforced hydroformed assembly as set forth in  claim 1  wherein said reinforcement has a generally rectangular cross-sectional shape.  
     
     
         7 . An internally reinforced hydroformed assembly as set forth in  claim 1  wherein said reinforcement comprises a pair of planar plates spaced axially, said at least one weld comprising a plurality of welds to join one end of said plates to an interior surface of said tubular member and another end of said plates to an opposed interior surface of said tubular member.  
     
     
         8 . An internally reinforced hydroformed assembly as set forth in  claim 1  wherein said reinforcement comprises a base wall, a pair of opposed side walls extending generally perpendicular from said base wall, and a pair of flange walls, one of said flange walls extending generally perpendicular from one of said side walls, said at least one weld comprising a plurality of welds to join said base wall to an interior surface of said tubular member and said flange walls to an opposed interior surface of said tubular member.  
     
     
         9 . An internally reinforced hydroformed assembly as set forth in  claim 1  wherein said reinforcement overlaps at least one interior corner of said tubular member.  
     
     
         10 . An internally reinforced hydroformed assembly as set forth in  claim 1  wherein said reinforcement overlaps substantially the entire interior surface of said tubular member.  
     
     
         11 . An internally reinforced hydroformed assembly as set forth in  claim 1  including a bracket disposed against an exterior surface of said tubular member opposite said reinforcement.  
     
     
         12 . A method of making an internally reinforced hydroformed assembly, said method comprising the steps of: 
 providing a reinforcement;    providing a channel shaped member with the reinforcement disposed therein;    forming the channel shaped member into a tubular member with the reinforcement internally therein; and    hydroforming the tubular member and reinforcement together to form a locally and internally reinforced hydroformed tubular member.    
     
     
         13 . A method as set forth in  claim 12  wherein said step of providing a reinforcement comprises forming the reinforcement into a cross-sectional shape from at least one of a group comprising planar, L, C, rectangular, and top hat.  
     
     
         14 . A method as set forth in  claim 12  including the step of forming a planar shaped member.  
     
     
         15 . A method as set forth in  claim 14  including the step of joining the reinforcement to a surface of the planar shaped member.  
     
     
         16 . A method as set forth in  claim 15  wherein said step of providing a channel shaped member with the reinforcement disposed therein comprises forming the planar shaped member with the reinforcement into a channel shaped member.  
     
     
         17 . A method as set forth in  claim 14  wherein said step of providing a channel shaped member with the reinforcement disposed therein comprises forming the planar shaped member into a channel shaped member.  
     
     
         18 . A method as set forth in  claim 17  wherein said step of providing a channel shaped member with the reinforcement disposed therein further comprises positioning the reinforcement in the channel shaped member.  
     
     
         19 . A method as set forth in  claim 12  including the step of welding the reinforcement to an interior surface of the tubular member prior to hydroforming.  
     
     
         20 . A method as set forth in  claim 12  including the step of welding an interface between ends of the tubular member prior to hydroforming.  
     
     
         21 . A method of making an internally reinforced hydroformed assembly, said method comprising the steps of: 
 forming a reinforcement;    forming a planar shaped member;    joining the reinforcement to a surface of the planar shaped member;    forming the planar shaped member with the reinforcement into a channel shaped member;    forming the channel shaped member into a tubular member with the reinforcement internally therein; and    hydroforming the tubular member and reinforcement together to form a locally and internally reinforced hydroformed tubular member.    
     
     
         22 . A method of making an internally reinforced hydroformed assembly, said method comprising the steps of: 
 forming a reinforcement;    forming a channel shaped member;    positioning the reinforcement in the channel shaped member;    joining the reinforcement to an interior surface of the channel shaped member;    forming the channel shaped member into a tubular member with the reinforcement internally therein; and    hydroforming the tubular member and reinforcement together to form a locally and internally reinforced hydroformed tubular member.