公开(公告)号：US10960748B2

公开(公告)日：2021-03-30

申请号：US16851703

申请日：2020-04-17

Applicant: Shape Corp.

Inventor： Joseph Robert Matecki ,  Mark Charles Stephens ,  Helen Weykamp

IPC: B60K1/04 ,  H01M2/10 ,  B60L50/60

Abstract: A vehicle battery tray includes a floor assembly that has elongated tray sections that attach together at lateral edge portions of adjacent tray sections to form a floor structure that supports vehicle batteries contained in the vehicle battery tray. The elongated tray sections each have a substantially consistent cross-sectional shape that extends longitudinally along a length of the respective tray section. A first tray section includes a first attachment feature at the lateral edge portion thereof and a second tray section includes a second attachment feature at the lateral edge portion thereof that corresponds with the first attachment feature. The first and second attachment features engage together at a longitudinal seam between the lateral edge portions of the first and second tray sections, such as to align upper surfaces of the first and second tray sections.

公开(公告)号：US20210053517A1

公开(公告)日：2021-02-25

申请号：US17094429

申请日：2020-11-10

Applicant: Shape Corp.

Inventor： Douglas S. Baas ,  Joseph R. Matecki ,  Shawn R. Jasman

IPC: B60R19/18 ,  B21C37/08 ,  B60R19/02 ,  B60R19/03

Abstract: A multi-tubular beam for a vehicle, such as a vehicle structure or a bumper reinforcement, includes an elongated beam formed with a metal sheet. The metal sheet has a central section and outer sections extending along a length of the metal sheet. The outer sections are disposed in opposing directions from the outer edges of the central section to provide adjacent first and second tubular portions. The central section forms a common center wall between the adjacent first and second tubular portions. A first edge portion of the metal sheet is disposed along and in parallel alignment with the center wall. The first edge portion is attached to the center wall at a first weld joint to form the first tubular portion. The first weld joint includes a weld material that extends through a thickness of the center wall and into a thickness of the first edge portion.

公开(公告)号：US10919351B1

公开(公告)日：2021-02-16

申请号：US16267931

申请日：2019-02-05

Applicant: Shape Corp.

Inventor： Cort C. Corwin ,  Kannan Ramamoorthy

IPC: B60D1/56 ,  B60D1/145 ,  B60R19/24 ,  B60D1/48 ,  B60R11/00

Abstract: A loading bracket assembly includes a base bracket having an engagement portion that is disposed at an interior area of a composite vehicle structural component and that is accessible through the first wall. A fastener may be attached to the engagement portion of the base bracket and may extend through an intermediate wall of the composite vehicle structural component and a supportive structure of the vehicle. The engagement portion of the base bracket is configured to engage a component or an accessory, such as a tow hook, that applies a loading force to the base bracket that is substantially transferred to the supportive structure and bypasses the composite vehicle structural component.

公开(公告)号：US20180186227A1

公开(公告)日：2018-07-05

申请号：US15862200

申请日：2018-01-04

Applicant: Shape Corp.

Inventor： Mark Charles Stephens ,  Joseph Robert Matecki ,  Ed C. Pendergrass

IPC: B60K1/04 ,  B60L11/18 ,  H01M2/10

CPC classification number: B60K1/04 ,  B60K2001/0438 ,  B60L50/66 ,  B60Y2306/01 ,  H01M2/1077 ,  H01M2/1083 ,  H01M2220/20 ,  Y02T10/7005

Abstract: A battery support structure for a vehicle includes a plurality of side reinforcement members and front and rear reinforcement members. The plurality of side reinforcement members are configured to extend longitudinally relative to an associated vehicle frame, and the front and rear reinforcement members are configured to extend laterally relative to the associated vehicle frame. A plurality of module nodes are attached between adjacent ends of the side reinforcement members and the front and rear members to together form a containment wall that generally surrounds a battery containment area. The plurality of module nodes comprise corner sections of the containment wall, such that a length of the side reinforcement members or the front and rear reinforcement members is selected to provide a desired respective length or width of the battery containment area.

公开(公告)号：US20180112298A1

公开(公告)日：2018-04-26

申请号：US15791834

申请日：2017-10-24

Applicant: Shape Corp.

Inventor： Helen Weykamp

IPC: C22F1/053 ,  B21B3/00 ,  B23K26/21

CPC classification number: C22F1/053 ,  B21B3/00 ,  B21B2001/228 ,  B21B2003/001 ,  B23K26/21 ,  B23K2103/10

Abstract: A method of forming and processing a high strength aluminum alloy for the production of a vehicle component includes providing a metal sheet that was rolled from an aluminum alloy. The sheet is heat treated through a first aging step of a set of aging steps that are necessary to achieve a T6 or a T7 temper state. Prior to achieving the T6 or a T7 temper state, the sheet is formed to a desired shape and welded in the desired shape to produce a desired vehicle component. Once formed, the vehicle component is heat treated through a remaining aging step to achieve a T6 or T7 temper state homogeneously throughout the vehicle component.

公开(公告)号：US09682674B2

公开(公告)日：2017-06-20

申请号：US14956518

申请日：2015-12-02

Applicant: Shape Corp.

Inventor： Cort C. Corwin ,  Toby K. Jacobson ,  Joseph R. Matecki ,  Ed C. Pendergrass

IPC: B60R19/03 ,  B60R19/12 ,  B60R19/18 ,  B60R19/24 ,  B29C70/52 ,  B29L31/30 ,  B29K105/08

CPC classification number: B60R19/03 ,  B29C70/523 ,  B29C70/525 ,  B29K2105/0809 ,  B29L2031/3044 ,  B60R19/12 ,  B60R19/18 ,  B60R19/24 ,  B60R2019/1853

Abstract: The present bumper impact beam includes pultruding polymer (e.g. thermoset polymer, preferably polyurethane) into continuous reinforcement (preferably carbon fibers or glass fibers), the reinforcement including fabrics selectively positioned and extending around corners for improved impact strength. The beam preferably has a 50%-70% fiber volume fraction that is relatively uniform throughout the part. A curved cooling support and/or beam design may be used to cause the cooled beam to have a sweep.

公开(公告)号：US08973957B2

公开(公告)日：2015-03-10

申请号：US14245017

申请日：2014-04-04

Applicant: Shape Corp.

Inventor： Cort Corwin ,  Joseph Matecki ,  Craig Oomen

IPC: B60R19/18 ,  B60R21/34 ,  B60R19/34

CPC classification number: B60R19/34 ,  B60R19/18 ,  B60R21/34 ,  B60R2019/1866 ,  B60R2021/343

Abstract: A vehicle bumper system comprises a bumper reinforcement beam and an energy absorber with top and bottom rows of similarly-shaped spaced-apart crush lobes in alternating relation for uniform impact resistance across the bumper system. The illustrated top row of crush lobes provides a high first force-deflection curve for high impact forces, and the bottom row of crush lobes provides a lower second force-deflection curve, for pedestrian reduced injury. An elongated sensor is positioned under shear walls of the top and bottom crush lobes, and is retained by tabs on the energy absorber. This positively retains the sensor in position on the bumper system, with few (or zero) separate fasteners, while facilitating quick assembly and reliable operation of the sensor tube.

Abstract translation: 车辆保险杠系统包括保险杠加强梁和能量吸收器，其具有彼此相似形状的间隔开的挤压叶片的顶部和底部行，其交替关系用于穿过保险杠系统的均匀的抗冲击性。 所示的顶排挤压凸耳为高冲击力提供了高的第一力 - 挠度曲线，而下排的挤压波瓣提供较低的第二力 - 偏转曲线，用于行人减少的伤害。 细长传感器位于顶部和底部挤压叶片的剪切壁下方，并由能量吸收器上的突片保持。 这样可以将传感器保持在保险杠系统上的位置上，同时具有很少的（或零）分离的紧固件，同时便于传感器管的快速组装和可靠的操作。

公开(公告)号：US20140377484A1

公开(公告)日：2014-12-25

申请号：US14258566

申请日：2014-04-22

Applicant: Shape Corp.

Inventor： Brian Oxley ,  Doug Witte ,  Joe Matecki ,  Martin Müller

IPC: B21C37/08

CPC classification number: B21D5/086 ,  B21D47/01 ,  B21D53/88 ,  Y10T428/13

Abstract: An apparatus comprises an uncoiling device for unrolling sheet material, an embossing device for embossing a series of crush initiating embossments into the sheet, a slitter to remove deformed edges of the sheet to facilitate welding, and a roll former with rolls configured to deform the sheet into a continuous tubular beam with walls each including some of the embossments, with the rolls being configured to clear the embossments but accurately form corners joining the walls. The apparatus further includes a welder welding abutting edges of the sheet together to fix the tubular beam, with the abutting edges being located inboard of an adjacent one of the corners but outboard of an outboard edge of adjacent ones of the embossments, and a cutoff device for cutting the continuous tubular beam into beam segments. A related method is also disclosed.

Abstract translation: 一种装置包括用于展开片材的开卷装置，用于将一系列压碎起始压花压印到片材中的压花装置，用于去除片材的变形边缘以便于焊接的分切机，以及具有辊的成形辊， 进入具有各自包括一些压花的壁的连续管状梁，其中辊构造成清除压花，但是准确地形成连接壁的拐角。 该设备还包括焊接器焊接该片材的边缘，以一起固定管状梁，其中邻接边缘位于相邻的一个角落的内侧，但邻近的一个凸起的外侧边缘的外侧，以及切断装置 用于将连续管状束切割成束段。 还公开了相关方法。

公开(公告)号：US08872060B2

公开(公告)日：2014-10-28

申请号：US13779310

申请日：2013-02-27

Applicant: Shape Corp.

Inventor： Thomas Johnson ,  Doug Witte ,  Daniel Gatti ,  Brian Oxley ,  Brian Malkowski

IPC: B23K26/00 ,  B21D39/00 ,  B23K37/00 ,  B23K1/20 ,  B23K1/14 ,  B21D5/14 ,  B21D9/10 ,  B21D11/08 ,  B21B15/00 ,  B60R19/02 ,  B21D5/08 ,  B21D53/88 ,  B21D51/16 ,  B23K26/24 ,  B23K26/20 ,  B60R19/18

CPC classification number: B60R19/18 ,  B21D5/086 ,  B21D5/14 ,  B21D51/16 ,  B21D53/88 ,  B23K26/0619 ,  B23K26/0846 ,  B23K26/20 ,  B23K26/24 ,  B23K26/242 ,  B23K26/32 ,  B23K37/0235 ,  B23K37/0435 ,  B23K2101/006 ,  B23K2101/18 ,  B23K2103/04 ,  B23K2103/50 ,  B60R19/023 ,  B60R2019/1813 ,  B60R2019/1826

Abstract: An apparatus forms a sheet into a beam having four exterior walls and a common center leg extending between an opposing two of the walls. The apparatus includes a roll former forming the sheet into the beam cross section, a welding station with top and bottom laser welders, and a weld box fixture having inwardly-biased external mandrels (biased by actuators) and outwardly-biased internal split mandrels (biased by springs) that interact to hold a desired shape of the beam in the weld fixture, and also includes a sweeping unit and cutoff device. By this arrangement, the internal and external mandrels, in combination with a bias of the actuators and springs, control a shape of the beam by flexure and movement of material of the sheet when in the weld box fixture during a welding process of the welder.

Abstract translation: 一种装置将片材形成为具有四个外壁和在相对的两个壁之间延伸的公共中心腿的梁。 该装置包括将片材形成为横截面的轧辊成型机，具有顶部和底部激光焊接机的焊接站以及具有向内偏置的外部心轴（由致动器偏置）和向外偏置的内部分离心轴（偏置 通过弹簧），其相互作用以在焊接夹具中保持梁的期望形状，并且还包括扫掠单元和切断装置。 通过这种布置，内部和外部心轴与致动器和弹簧的偏压相结合，在焊接机的焊接过程期间在焊接箱固定装置中通过片材的材料的挠曲和移动来控制梁的形状。

公开(公告)号：US08763437B2

公开(公告)日：2014-07-01

申请号：US13664791

申请日：2012-10-31

Applicant: Shape Corp.

Inventor： Richard D. Heinz ,  Bryan E. Gould

IPC: B21D21/00

CPC classification number: B21D5/08 ,  B21D5/086 ,  B21D7/08 ,  B21D53/88

Abstract: An apparatus includes a roll former with rolls configured to form a structural beam from sheet material, and a sweep unit for longitudinally sweeping a beam in any of vertical, horizontal, or combination directions. The sweep unit has a first pair of forming rolls positioned to engage first opposing sides of the structural beam and has a second pair of forming rolls positioned to engage second opposing sides of the structural beam. The sweep unit movably supports the first and second pairs of forming rolls so that any selected one of the forming rolls continuously engages an associated side of the structural beam while an associated one of the forming rolls opposing the selected one forming roll moves downstream and around the selected one forming roll. This provides a very stable beam-bending condition promoting dimensional stability during the sweeping process, and hence dimensional accuracy and repeatability.

Abstract translation: 一种装置包括具有构造成从片材形成结构束的辊的辊轧机，以及用于沿垂直，水平或组合方向中的任何一个纵向扫掠梁的扫掠单元。 扫掠单元具有第一对成形辊，其定位成与结构梁的第一相对侧接合并且具有定位成接合结构梁的第二相对侧的第二对成形辊。 吹扫单元可移动地支撑第一和第二对成型辊，使得任何选定的成型辊中的一个成形辊连续地接合结构梁的相关联的一侧，而与所选择的一个成形辊相对的相关联的一个成形辊移动到下游并且围绕 选择一个成型辊。 这提供了非常稳定的梁弯曲条件，以提高扫掠过程中的尺寸稳定性，从而提高尺寸精度和重复性。