Method for producing a support and motor vehicle support

Patent metadata

Field	Value
Publication number	US-12208550-B2
Application number	US-202117243862-A
Country	US
Kind code	B2
Filing date	Apr 29, 2021
Priority date	May 13, 2020
Publication date	Jan 28, 2025
Grant date	Jan 28, 2025

Abstract

A method for producing a support for a motor vehicle, in particular a dashboard support, comprises the following steps: producing a core from a foam material and at least partially surrounding the core with a unidirectional layer to form a reinforced core. A resulting support for a motor vehicle has a core made of a foam material, wherein the core is at least partially provided with a unidirectional layer.

First claim

What is claimed is:

1. A method for producing a dashboard support for a motor vehicle, the method comprising the steps of:
producing an elongate core from a foam material;
at least partially surrounding the elongate core with a unidirectional layer to form a reinforced elongate core, wherein the unidirectional layer comprises a unidirectional fiber-reinforced tape which has fibers embedded in a polymer and oriented parallel to one another and in one direction;
arranging fastening structures along a length of the reinforced elongate core between first and second ends of the reinforced core; and
overmolding the reinforced elongate core and the fastening structures with a thermoplastic material to couple the fastening structures with the reinforced elongate core.

2. The method according to claim 1 , further comprising the step of layering the tape around the core.

3. The method according to claim 1 , further comprising the step of winding the tape around the core.

4. The method according to claim 1 , further comprising the step of adhesively bonding the unidirectional layer to the core.

5. The method according to claim 1 , wherein the foam material for the core is a polymethacrylimide.

6. The method according to claim 1 , wherein the step of producing the core comprises producing the core by injection molding.

7. A method for producing a dashboard support for a motor vehicle, the method comprising the steps of:
producing an elongate core from a foam material by injection molding;
at least partially surrounding the elongate core with a unidirectional layer to form a reinforced elongate core, wherein the unidirectional layer comprises a unidirectional fiber-reinforced tape which has fibers embedded in a polymer and oriented parallel to one another and in one direction;
inserting the reinforced elongate core into a secondary mold;
arranging fastening structures on a length of the reinforced elongate core between first and second ends of the reinforced elongate core; and
overmolding to secure the fastening structures onto the reinforced elongate core.

8. The method according to claim 7 , further comprising the step of layering the tape around the core.

9. The method according to claim 7 , further comprising the step of winding the tape around the core.

10. The method according to claim 7 , further comprising the step of adhesively bonding the unidirectional layer to the core.

11. The method according to claim 7 , wherein the foam material for the core is a polymethacrylimide.

12. A dashboard support for a motor vehicle, the support comprising:
a core made of a foam material via injection molding;
a unidirectional layer at least partially surrounding the core to form a reinforced core, wherein the unidirectional layer comprises a unidirectional fiber-reinforced tape which has fibers embedded in a polymer and oriented parallel to one another and in one direction; and
at least one fastening structure inserted partially within the core during the injection molding and coupled with a body of the reinforced core via overmolding of a thermoplastic material.

13. The method according to claim 7 , further comprising:
inserting the foam material into a primary mold to form the elongate core via the injection molding.

14. The dashboard support according to claim 12 , wherein the at least one fastening structure comprises at least one of a clamp, a clip and an insert.

15. The method according to claim 7 , wherein the at least one fastening structure comprises at least one of a clamp, a clip and an insert.

16. The method according to claim 1 , wherein the at least one fastening structure comprises at least one of a clamp, a clip and an insert.

Assignees

• Ford Global Tech Llc

Inventors

• Baranowski Thomas
• Broda Maik
• Franzen Markus
• Rebmann Pascal

Classifications

• B29C44/42

  using pressure difference, e.g. by injection or by vacuum · CPC title

• B29K2033/26

  Polymers of acrylamide or methacrylamide · CPC title

• B29L2031/3008

  Instrument panels · CPC title

• B29C2045/0079

  applying a coating or covering · CPC title

• B29C45/0001

  characterised by the choice of material · CPC title