Automobile roof rack made of continuous fiber thermoplastic composite

Patent metadata

Field	Value
Publication number	US-10059272-B2
Application number	US-201514946498-A
Country	US
Kind code	B2
Filing date	Nov 19, 2015
Priority date	Apr 28, 2015
Publication date	Aug 28, 2018
Grant date	Aug 28, 2018

Abstract

An automobile roof rack made of a continuous fiber thermoplastic composite may include a resin body having a roof rack shape, and an insert-reinforcing layer formed on an inner surface of the resin body to be integrated with the resin body into a single body and made of a continuous fiber thermoplastic composite (CFT).

First claim

What is claimed is:

1. An automobile roof rack made of a continuous fiber thermoplastic composite, the automobile roof rack comprising:
a resin body having a roof rack shape;
an insert-reinforcing layer formed on an inner surface of the resin body to be integrated with the resin body into a single body and made of a continuous fiber thermoplastic composite (CFT); and
a plurality of reinforcing protrusions that is formed on and integrated with one surface of the insert-reinforcing layer and is arranged at intervals in a lengthwise direction of the roof rack,
wherein an end of the reinforcing protrusion is provided with a reinforcing recess that has an opening near the resin body,
wherein a connection to be inserted into the reinforcing recess is formed in the insert-reinforcing layer, and
wherein mating between the reinforcing recess and the connection protrusion enhances coherence between the insert-reinforcing layer and the reinforcing protrusion.

2. The automobile roof rack according to claim 1 , wherein the roof rack including the resin body, the insert-reinforcing layer, and the reinforcing protrusions has a “U” shape that is open on one side.

3. The automobile roof rack according to claim 2 , wherein an opening of the roof rack is disposed near a roof panel, forming a closed space between the roof rack and the roof panel.

4. The automobile roof rack according to claim 1 , wherein the reinforcing recess is tapered to a bottom thereof and has a shape in which a diameter thereof decreases toward the bottom from an entrance portion thereof, thereby enhancing coherence between the reinforcing recess and the connection protrusion.

5. The automobile roof rack according to claim 1 , wherein the insert-reinforcing layer is separately manufactured from the resin body, then put into an injection mold, and finally insert-molded along with the resin body and the reinforcing protrusion so that the resin body, the insert-reinforcing layer, and the reinforcing protrusion are integrated with each other to become a single body, forming the roof rack.

6. The automobile roof rack according to claim wherein when forming the reinforcing protrusions on one side of the insert-reinforcing layer through an injection molding process, the connection protrusion of the insert-reinforcing layer is inserted into the reinforcing recess of the reinforcing protrusion.

7. The automobile roof rack according to claim 2 , wherein the resin body comprises a material having a composition containing 50 to 70 weight % of nylon 6, 30 to 50 weight % of mineral glass fiber (MGF), and minimal impurities.

8. The automobile roof rack according to claim 2 , wherein the resin body comprises a material having a composition containing 60 weight % of nylon 6 and 40 weight % of mineral glass fiber (MGF).

9. The automobile roof rack according to claim 2 , wherein the insert-reinforcing layer made of a continuous fiber thermoplastic composite comprises a material having a composition containing 40 to 60 weight % of nylon 6, 40 to 60 weight % of glass fiber (GF), and minimal impurities.

10. The automobile roof rack according to claim 2 , wherein the insert-reinforcing layer made of a continuous fiber thermoplastic composite comprises a material having a composition containing 50 weight % of nylon 6 and 50 weight % of glass fiber (GF).

11. The automobile roof rack according to claim 2 , wherein the insert-reinforcing layer has a thickness of 0.6 to 1.3 mm.

Assignees

• Hyundai Motor Co Ltd
• Kia Motors Corp
• Lg Hausys Ltd

Inventors

• Kim Hyun Gyung
• Lee Seung Mok
• Lee Jeong Ho
• Park Chun Ho
• Hong Sung Jun

Classifications

• C08L77/06

  Polyamides derived from polyamines and polycarboxylic acids (C08L77/10 takes precedence) · CPC title

• C08L77/02 Primary

  Polyamides derived from omega-amino carboxylic acids or from lactams thereof (C08L77/10 takes precedence) · CPC title

• C08K7/14

  Glass · CPC title

• B60R9/04 Primary

  Carriers associated with vehicle roof (B60R9/08 takes precedence) · CPC title