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1. EP0876265 - BUMPER, AND THE FABRICATION THEREOF

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Claims

1. A method for fabrication of a structural beam or bumper, especially for a vehicle, comprising an elongated profile which upon collision is adapted for absorbing collision energy and forces,
   comprising the steps of
   providing a complete and hollow blank having, along its more or less arched extension, a center portion (3), side portions (2) at each side of said center portion (3) and terminal portions (4) and
   processing said blank to a compressed or folded cross section in said terminal portion (4),
    characterized by the steps of
   processing said blank to an outwardly pressed cross section in said center portion (3) and
   processing said blank with a substantially unchanged basic cross section in each side portion (2).
  2. The method of claim 1,
    characterized by the step of processing said blank to an arched extension.
  3. The method of claim 1 or 2,
    characterized in that there is used a hollow blank the inside thereof being defined by a first wall portion (2a), an arched second wall portion (2b) and yoke portions (2c) extending substantially perpendicularly from the outer wall portion (2a), wherein
   said center portion (3) is processed to a substantially trapeze shaped cross section comprising a first center wall portion (3a) having substantially the same height (H) as said blank, a second center wall portion (3b) of less height, and substantially inclined center yoke portions (3c) therebetween, and
   said terminal portions (4) are processed to a cross section profile comprising a first terminal wall portion (4a) having the same height (H) as said blank, a second terminal wall portion (4b) having a larger, equal or less height (H) and intermediate, arched or wavy terminal yoke portions (4c).
  4. The method of any preceding claim,
    characterized in that as said blank there is used an extruded profile (2) having a closed cross section, said first and second wall portions (2a, 2b) having a larger wall thickness than the wall thickness of said intermediate yoke portions (2c).
  5. The method of any preceding claim,
    characterized in that the end portions of said blank are processed to attachment portions which are provided with a net parallel surface for attachment to a side beam in the vehicle.
  6. The method of any preceding claim,
    characterized in that the blank is processed to a profile which is substantially symmetrical about a center plane running in the longitudinal direction of the vehicle, and is provided with an outer mantle of plastic material.
  7. The method of any preceding claim,
    characterized in that the processing of the blank takes place in a first stretching or pressing to a main shape, especially a vaguely arched shape in the longitudinal direction of the blank, whereafter the profile at the same time or in a subsequent processing operation is processed at the center portion (3) and the terminal portions (4), but in opposite processing direction for said portions.
  8. The method of any preceding claim,
    characterized in that the blank is processed by an outer processing, for example by means of mechanical tools.
  9. The method of any preceding claim,
    characterized in that the blank is processed by means of hydroforming.
  10. A structural beam or bumper, fabricated by the method of any preceding claim.
  11. The beam or bumper of claim 10, especially for a vehicle, comprising an elongated profile which upon collision is adapted for absorbing collision energy and forces, the beam or bumper being prepared from a complete and hollow blank and being further provided with different cross sections along its more or less arched extension, wherein
   said beam or bumper comprises a center portion (3), side portions (2) at each side of said center portion (3) and terminal portions (4) and
   said beam or bumper has a compressed or folded cross section at each of said terminal portions (4), and that the beam or bumper in addition has a substantially unchanged basic cross section at each of said side portions (2), and has an outwardly pressed cross section relative to said basic cross section at said center portion (3).
  12. The beam or bumper of claim 10 or 11,
    characterized in that
   it has an arched extension.
  13. The beam or bumper of any of claims 10 to 12,
    characterized in that
   the inside of each of said side portions (2) is defined by a first wall portion (2a), an arched inner wall portion (2b), and yoke portions (2c) extending substantially perpendicularly from said outer wall portion (2a),
   said center portion (3) has a substantially trapeze shaped cross section defined by a first center wall portion (3a) having the same height (H) as said side portions (2), a second center wall portion (3b) of less height, and substantially slanted yoke portions (3c) therebetween, and
   said terminal portions (4) have a first terminal wall portion (4a) having substantially the same height (H) as said side portions (2), a second terminal wall portion (4b) having larger, equal or less height (H1) and intermediate, arched or wavy yoke portions (4c).
  14. The beam or bumper of any of claims 10 to 13,
    characterized in that it comprises a closed cross section (2) wherein said first and second wall portions (2a, 2b) have a relatively larger wall thickness than the wall thickness of said intermediate yoke portions (2c).
  15. The beam or bumper of any of claims 10 to 14,
    characterized in that said terminal portions (4) merge into attachment portions which are provided with a net parallel surface for attachment to a side beam in the vehicle.
  16. The beam or bumper of any of claims 10 to 15,
    characterized in that
   its profile is provided substantially symmetrical about a center plane running in the longitudinal direction of the vehicle, and
   it is provided with an outer mantle of plastic material.