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US-20260124795-A1 - POLYMERIC ARTICLES FOR APPLICATIONS IN VEHICLES AND METHODS OF MAKING THE SAME

US20260124795A1US 20260124795 A1US20260124795 A1US 20260124795A1US-20260124795-A1

Abstract

A molded article is disclosed made from a composition comprising a thermoplastic polymer for use as an impact resistant structure for a vehicle, for example an off-road vehicle. The molded article can have an average thickness or a maximum thickness of 5 mm to 14 mm and is configured to absorbed at least 355 joules of force without forming an open puncture from an impact surface of the article to an opposing surface of the article.

Inventors

  • Daniel CORDIDO
  • Jordan PELZI
  • Eric Palomaki
  • Vinod Arora

Assignees

  • CORE MOLDING TECHNOLOGIES, INC.

Dates

Publication Date
20260507
Application Date
20251219

Claims (17)

  1. 1 . A method of manufacturing an impact resistant article for a vehicle, comprising: injection molding a composition comprising a thermoplastic polymer to produce an impact resistant article for a vehicle configured to absorbed 355 Joules of force without forming an open puncture from an impact surface of the article to an opposing surface of the article.
  2. 2 . The method of claim 1 , wherein the injection molding is conducted in the presence of nitrogen gas in an amount of 5% to 15% by volume of the total volume of the composition.
  3. 3 . The method of claim 1 , wherein the thermoplastic polymer additionally includes glass fiber, wherein the glass fiber is from 30% to 65% by weight of the total weight % of the composition.
  4. 4 . The method of claim 1 , wherein the thermoplastic polymer additionally includes uni-or single directional fiberglass, wherein the fiberglass is from 30% to 65% by weight of the total weight % of the composition.
  5. 5 . The method of claim 1 , wherein the article has an average thickness or a maximum thickness of 3 mm to 14 mm.
  6. 6 . The method of claim 1 , additionally comprising: shaping the article into a skid plate for an off-road vehicle, wherein the skid plate can absorb 355 Joules of force from a stick or a branch without forming an open puncture from an impact surface of the skid plate to an opposing surface of the skid plate when the off-road vehicle travels at a speed of 16 mph or less.
  7. 7 . The method of claim 1 , wherein the vehicle is a boat hull, and the method additionally comprises shaping the article into a boat hull.
  8. 8 . The method of claim 1 , wherein the thermoplastic polymer is selected from a group consisting of an acrylonitrile butadiene styrene (ABS) homo- or co-polymer, a polypropylene homo- or co-polymer, a polyethylene homo- or co-polymer, a polystyrene homo- or co-polymer, a polyamide homo- or co-polymer, and a high-density polyethylene (HDPE) homo-or co-polymer.
  9. 9 . An off-road vehicle having a skid plate with an average thickness or maximum thickness of 3 mm to 14 mm for protection of occupants against penetration of objects encountered during normal course of off-road operation made in accordance with the method of claim 1 .
  10. 10 . The off-read vehicle of claim 9 , wherein the skid plate prevents penetration of branches and sticks through the skid plate at a speed of up to 16 miles per hour.
  11. 11 . A method of manufacturing an impact resistant article for a vehicle, comprising: molding a composition comprising a thermoplastic polymer to produce an article having an average thickness or a maximum thickness of 3 mm to 14 mm and configured to absorbed 355 joules of force without forming an open puncture from an impact surface of the article to an opposing surface of the article.
  12. 12 . The method of claim 11 , wherein the molding includes a molding operation selected from a group consisting of injection molding, transfer injection molding, low pressure injection molding, compression molding, and compression transfer molding.
  13. 13 . The method of claim 11 , wherein the molding is a gas-assisted injection molding process with nitrogen gas being applied in an amount of 5% to 15% by volume of the total volume of the composition.
  14. 14 . The method of claim 11 , wherein the thermoplastic polymer is homopolymer, a copolymer, a random polymer, or a graft polymer having units selected from a group consisting of an acrylic; a polyester; an acrylonitrile butadiene styrene (ABS); a polyamide or a nylon; a polylactic acid or a polylactide; a polybenzimidazole ((PBI); a polycarbonate (PC); a polyether sulfone (PES) or a polysulfone; a polyoxymethylene ((POM); a polyaryletherketone (PAEK); a polyetherimide (PEI); a polyethylene; a polyphenylene oxide (PPO); a polyphenylene sulfide (PPS); a polypropylene (PP); a polystyrene; a polyvinyl; a polyvinyl chloride (PVC); a polyvinylidene fluoride (PVDF); a polytetrafluoroethylene (PTFE); a high-density polyethylene (HDPE), and combination or mixtures thereof.
  15. 15 . The method of claim 11 , wherein the composition additionally includes glass fiber, wherein the glass fiber is from 30% to 65% by weight of the total weight % of the composition.
  16. 16 . The method of claim 11 , wherein the composition additionally includes uni-or single directional fiberglass, wherein the fiberglass is from 30% to 65% by weight of the total weight % of the composition.
  17. 17 . An off-road vehicle having a skid plate comprising a molded thermoplastic sheet layer or sheet layers, wherein the skid plate has an average thickness or maximum thickness of 3 mm to 14 mm, and is configured to absorb 355 joules of force without forming an open puncture from an impact surface of the skid plate to an opposing surface of the skid plate; and wherein the skid plate prevents penetration of branches and sticks through the skid plate at a speed of up to 16 miles per hour.

Description

CROSS-REFERENCE TO RELATED APPLICATION This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63/716,661 , filed Nov. 5, 2024, which is incorporated by reference herein in its entirety. FIELD OF INVENTIONS The present inventions relate to articles made from polymeric materials and methods of making the same. More specifically, the present inventions relate to molded thermoplastic materials with improve impact resistance and high wear use properties for vehicles. BACKGROUND The popularity of off-road vehicles (ORVs), a category of vehicles which includes recreational off-road vehicles (RORVs), all-terrain vehicles (ATVs), and utility task vehicles (UTVs), has dramatically increased and continues to rise. In 1998 an estimated 35,000 units were sold in the United States. The number of units sold has risen to well over 2 million. ORVs are intended to be driven off-road or off-highway and are specifically designed to have all-terrain capabilities. Common uses for ORVs include farm work, hunting, recreation, and trail riding. ORVs are driven in wooded areas and trails, where the vehicles are intended to traverse hazardous and rough terrains with pits, rocks, tree branches, and sticks. The U.S. Consumer Product Safety Commission (CPSC) has determined that there is an unreasonable risk of injury and death associated with ORVs caused by debris penetration, even if operated at lower speeds. Tree branches and sticks are known to crack and penetrate through the floorboard of the underside and into the occupant area or cabin. When such penetration occurs, there is a risk that the branch or other debris penetrates far enough into the vehicle to injure or cause death to the occupants. Reported injuries have involved lacerations, bruises, abrasions, broken bones, and impalement of lower body extremities and the abdomen. CSPC reported over 100 incidents of injury and 6 fatalities between 2009 and 2021 involving debris penetration and well over 600 incidences of debris cracking or breaking through the floorboards which could have led to injuries. With ORVs (as well as other type of trucks and marine vehicles) composite body parts are rapidly replacing metals because composites offer many advantages over their counterpart metal components. Composite materials are inexpensive, and the parts are easier and less expensive to manufacture, especially customized components. Moreover, composite components are easier to install, have a higher degree of recyclability, are rust and corrosion resistant, light weight, flexible, dent resilient, and provide a greater degree of noise reduction. However, current composites in the market have failed to provide the same strength and protection offered by the metallic parts, especially for skid plates and boat hulls where improved impact and penetration resistance, toughness, and durability is of extreme importance. Simple glass fiber, glass reinforced material, and un-reinforced plastic materials cannot withstand the stresses endured in ORV use, unless the component is made very thick—which makes the article unpractical and cost prohibitive. Accordingly, there is a great need for suitable materials and processes to produce cost-effective ORV (and other vehicular) components of various shapes and designs with improved impact and penetration resistance, toughness, and durability. SUMMARY In accordance to one aspect of the inventions, a method of manufacturing an impact resistant article for a vehicle is provided, comprising: injection molding a composition comprising a thermoplastic polymer to produce an impact resistant article for a vehicle configured to absorbed 355 Joules of force without forming an open puncture from an impact surface of the article to an opposing surface of the article. The injection molding can be conducted in the presence of nitrogen gas in an amount of 5% to 15% by volume of the total volume of the composition. The thermoplastic polymer can additionally include glass fiber, wherein the glass fiber is from 30% to 65% by weight of the total weight % of the composition. The thermoplastic polymer can additionally include uni- or single directional fiberglass, wherein the fiberglass is from 30% to 65% by weight of the total weight % of the composition. The article can have an average thickness or a maximum thickness of 3 mm to 14 mm. The method can include shaping the article into a skid plate for an off-road vehicle, wherein the skid plate can absorb 355 Joules of force from a stick or a branch without forming an open puncture from an impact surface of the skid plate to an opposing surface of the skid plate when the off-road vehicle travels at a speed of 16 mph or less. The vehicle can be a boat hull, and the method additionally comprises shaping the article into a boat hull. The thermoplastic polymer can be selected from a group consisting of an acrylonitrile butadiene styrene (ABS) homo-or co-polymer, a polypropylene homo-or co-poly