EP-4737276-A2 - REINFORCEMENT STRUCTURE

EP4737276A2EP 4737276 A2EP4737276 A2EP 4737276A2EP-4737276-A2

Abstract

A structural member, preferably a structural member that reinforces a body of an automobile, comprising: i) a first carrier and a second carrier, each carrier including a plurality of interconnecting ribs, each carrier further including one or more projections extending from exterior walls of each carrier; and ii) one or more secondary members secured to one or more surfaces of each carrier; iii) an adhesive material disposed on the first carrier, the second carrier, or both, wherein the first carrier and the second carrier are bonded to each other via the adhesive material; wherein the carriers and the one or more secondary members are different materials; wherein the first carrier and the second carrier are overmolded around one or more surfaces of the one or more secondary members; and wherein the plurality of interconnecting ribs form one or more cavities within the first carrier, the second carrier, or both.

Inventors

RICHARDSON, HENRY E.

Assignees

Zephyros, Inc.

Dates

Publication Date: 20260506
Application Date: 20200312

Claims (15)

A structural member, preferably a structural member that reinforces a body of an automobile, comprising: i) a first carrier and a second carrier, each carrier including a plurality of interconnecting ribs, each carrier further including one or more projections extending from exterior walls of each carrier; and ii) one or more secondary members secured to one or more surfaces of each carrier; iii) an adhesive material disposed on the first carrier, the second carrier, or both, wherein the first carrier and the second carrier are bonded to each other via the adhesive material; wherein the carriers and the one or more secondary members are different materials; wherein the first carrier and the second carrier are overmolded around one or more surfaces of the one or more secondary members; and wherein the plurality of interconnecting ribs form one or more cavities within the first carrier, the second carrier, or both.
The structural member according to claim 1, wherein the one or more cavities include a cutout near the one or more surfaces of the first carrier, the second carrier, or both that abuts the one or more secondary members.
The structural member according to any of the preceding claims, wherein after bonding, the first carrier and the second carrier form a clamshell shape and the one or more secondary members are positioned within the clamshell shape.
The structural member according to any of the preceding claims, wherein a first portion of the ribs are linear segments and a second portion of the ribs are arcuate segments.
The structural member according to any of the preceding claims, wherein the adhesive material is disposed on the one or more projections and the one or more projections of the first carrier and the second carrier abut one another to form the bond.
The structural member according to any of the preceding claims, wherein one or more mechanical fasteners temporarily connect the first carrier and the second carrier together during a curing time of the adhesive material.
The structural member according to any of the preceding claims, wherein the adhesive is an epoxy-based material, and the structural member reinforces a body of an automobile.
The structural member according to any of the preceding claims, wherein (i) the secondary member functions to secure, connect, or both the structural member to the vehicle structure, one or more vehicle components, or a combination thereof, and/or (ii) the thickness of the secondary member is about 1 mm or more and the thickness of the secondary member is about 6 mm or less, and optionally the thickness of the secondary member is uniform throughout substantially the entire secondary member.
The structural member according to any of the preceding claims, wherein the first carrier of the structural member includes a first set of through holes that mate with a second set of through holes on a second carrier, and when the first set of through holes is aligned with the second set of through holes, one or more fasteners extend through the first and second carrier to temporarily or permanently secure the first and second carrier together.
The structural member according to any of the preceding claims, wherein the first carrier and the second carrier have complimentary shapes so that, when secured to another, an overall desired shape is formed; and/or a carrier of the structural member includes one or more steps, one or more ledges, one or more flanges, one or more tabs, one or more gussets, one or more channels, or a combination thereof.
The structural member according to any of the preceding claims, wherein the structural member includes one or more through holes, and wherein the through holes are located in a carrier.
The structural member according to any of the preceding claims, wherein a carrier of the structural member include a first carrier component that is secured to a second carrier component via one or more adhesives, one or more fasteners, or a combination thereof.
The structural member according to claim 10, wherein the through holes function to receive one or more fasteners to secure the structural member to one or more vehicle components, a vehicle structure, one or more additional structural member components, or a combination thereof, and optionally the through holes include a reinforcement member that is a polymer or a metal, and optionally the reinforcement member is a sleeve inserted into and extending through the through hole.
The structural member according to any of the preceding claims, wherein the structural member includes one or more fasteners that function to secure the structural member to one or more components of a vehicle, a vehicle structure, or both and/or to secure the first carrier and the second carrier together; and optionally the fasteners are integrally formed with a carrier.
The structural member according to any of the preceding claims, wherein the first carrier includes a first projection and a second projection, and the first projection and the second projection are positioned near opposing terminal ends of the first carrier, and optionally wherein the second carrier includes a first projection and a second projection, and the first projection and the second projection are positioned near opposing terminal ends of the second carrier.

Description

FIELD The present invention generally relates to structural members, and more particularly to hybrid material structural members for use in providing reinforcement and support to sections of one or more structures. BACKGROUND Transportation vehicles frequently utilize structural members to form, support, reinforce, or a combination thereof certain vehicle structures. Unfortunately, such members tend to be formed of relatively heavy materials, adding undesirable weight to the vehicle. For some applications, it has become popular in recent years to employ a polymeric carrier structure in combination with a secondary material, such as an expandable adhesive material as part of the reinforcement. However, even these materials may add significant weight and can be costly and time consuming to manufacture. Moreover, the materials used to form the structural members may be configured to increase structural stiff of the structural member or increase energy absorption of the structural member. However, the structural member may as a result be too stiff for sufficient energy absorption, too flexible for sufficient structural stiffness, or both. Additionally, it may be difficult to provide sufficient structural support to certain vehicle structures using more lightweight materials, thereby increasing the risk of damage or breakage of the structural members, the vehicle structures being support by the structural members, or both. Examples of structural members can be found in U.S. Patent Nos. 6,932,421; 6,921,130; 6,920,693; 6,890,021; and 6,467,834, all of which are incorporated by reference herein for all purposes. Thus, there remains a need for structural reinforcements that include more lightweight materials while maintaining the necessary strength to support one or more vehicle structures or vehicle components. What is needed is a lightweight structural member that includes one or more strengthening features. There remains a need for structural members that may provide increased customization and tunability based on a desired application. What is needed is a structural member that may be configured to attach to a vehicle structure, one or more vehicle components, or both using a plurality of attachment features. There remains a need for a structural member that is cost-effective and easy to manufacture. What is needed is a structural member formed using a combination of time-efficient manufacturing techniques. There remains a need for a structural member that may be secured to a vehicle structure, vehicle component, or both free of an increase in temperature. What is needed is a structural member having one or more adhesives that cure at room temperature. SUMMARY The present teachings meet one or more of the above needs by the improved devices and methods described herein. The present teachings meet one or more of the present needs by providing a structural member comprising: (i) a first carrier and a second carrier, each carrier including a plurality of interconnecting ribs, each carrier further including one or more projections extending from exterior walls of each carrier; (ii) one or more secondary members secured to one or more surfaces of each carrier; and (iii) an adhesive material disposed on the first carrier, the second carrier, or both, wherein the first carrier and the second carrier are bonded to each other via the adhesive material. The present teachings meet one or more of the present needs by providing a structural member, wherein: the adhesive material is cured at room temperature to bond the first carrier and the second carrier; the carriers and the one or more secondary members are different materials; the carriers are a polyamide material and the one or more secondary members are a carbon fiber reinforced thermoplastic; the adhesive material is disposed on the one or more projections and the one or more projections of the first carrier and the second carrier abut one another to form the bond; one or more mechanical fasteners temporarily connect the first carrier and the second carrier together during a curing time of the adhesive material; one or more through holes of the first carrier and one or more through holes of the second carrier are aligned so that the mechanical fasteners extend through the aligned one or more through holes, and after curing of the adhesive material to bond the first carrier and the second carrier, the one or more through holes of the first carrier and the one or more through holes of the second carrier are configured to mount the structural member to one or more structures of a vehicle; after bonding, the first carrier and the second carrier form a clamshell shape and the one or more secondary members are positioned within the clamshell shape; the first carrier and the second carrier are overmolded around one or more surfaces of the one or more secondary members; the curing time of the adhesive material is unaffected by heating the adhesive material to a temperature o