Hybrid reinforcement structure

Patent metadata

Field	Value
Publication number	US-12240215-B2
Application number	US-202217719761-A
Country	US
Kind code	B2
Filing date	Apr 13, 2022
Priority date	Nov 7, 2008
Publication date	Mar 4, 2025
Grant date	Mar 4, 2025

Abstract

A structural reinforcement for insertion into a cavity of a vehicle structure including a base reinforcing portion, an expandable material and a localized reinforcement is disclosed. The localized reinforcement is placed within the structural reinforcement at a location of anticipated increased deformation during vehicle impact in an effort to reduce deformation and control the load distribution post-impact.

First claim

What is claimed is:

1. A structural reinforcement for insertion into a cavity of an automotive vehicle, the structural reinforcement comprising:
i) an elongated base reinforcing portion having:
a) a longitudinal axis,
b) a network of ribs, and
c) notches formed in opposing walls of the elongated base reinforcing portion;

ii) an expandable polymeric material located at least partially on the elongated base reinforcing portion; and
iii) a localized reinforcement aligned generally parallel with the longitudinal axis and located within the notches of the elongated base reinforcing portion; and
wherein the ductility of the elongated base reinforcing portion is less than the ductility of the localized reinforcement.

2. The structural reinforcement of claim 1 , wherein the localized reinforcement includes a fastening means that fastens the localized reinforcement to a vehicle structure or to the base reinforcing portion.

3. The structural reinforcement of claim 2 , wherein the fastening means attaches to any mounting bracket, a seat belt mechanism or retractor, a pull handle bracket, a roof rack, a mirror bracket, a sunroof bracket, a bumper bracket, a hinge component, a chassis mount bracket, an engine bracket, a suspension component, or a radiator bracket.

4. The structural reinforcement of claim 1 , wherein the localized reinforcement is made of a metallic material selected from steel, aluminum, titanium, nickel, magnesium, an alloy, a transition metal, or any combination thereof.

5. The structural reinforcement of claim 1 , wherein the localized reinforcement is made of polyurethanes, polyurethane composites, or any combination thereof.

6. The structural reinforcement of claim 1 , wherein the localized reinforcement is substantially covered by the elongated base reinforcing portion, the expandable polymeric material, or both.

7. The structural reinforcement of claim 1 , wherein the localized reinforcement is a composite material.

8. The structural reinforcement of claim 1 , wherein the localized reinforcement has an outer surface and at least a portion of the outer surface is in contact with the expandable polymeric material after expansion.

9. The structural reinforcement of claim 1 , wherein the expandable polymeric material has a ductility ratio of about 2.5.

10. The structural reinforcement of claim 1 , wherein the localized reinforcement has a generally curved or U-shaped profile.

11. The structural reinforcement of claim 1 , wherein the elongated base reinforcing portion is a metal part, a composite part, a polymeric part, or any combination thereof.

12. The structural reinforcement of claim 1 , wherein the localized reinforcement has one or more visible exposed surfaces after expansion of the expandable polymeric material.

13. The structural reinforcement of claim 1 , wherein the structural reinforcement includes a top portion, a middle portion, and a bottom portion so that the localized reinforcement is only in contact with the middle portion.

14. The structural reinforcement of claim 1 , wherein the expandable polymeric material is an epoxy-based material.

15. The structural reinforcement of claim 1 , wherein the localized reinforcement is made of a material that is dissimilar from and has a higher tensile strength than the material of the elongated base reinforcing portion so that upon impact in an impact deformation region, a severity of deformation is reduced as compared to a part without the localized reinforcement.

16. The structural reinforcement of claim 1 , wherein the network of ribs is disposed outward from the localized reinforcement.

17. The structural reinforcement of claim 1 , wherein the network of ribs is disposed over the localized reinforcement.

18. The structural reinforcement of claim 1 , wherein the notches extend partially into the opposing walls of the elongated base reinforcing portion.

19. The structural reinforcement of claim 1 , wherein the notches extend continuously along the longitudinal axis of the elongated base reinforcing portion.

Assignees

• Zephyros Inc

Inventors

• Richardson Henry E
• Qian Xuping
• Hulett Gary

Classifications

• B32B2605/00

  Vehicles · CPC title

• B32B2305/08

  Reinforcements · CPC title

• B32B15/08

  of synthetic resin · CPC title

• B32B3/28

  characterised by a layer comprising a deformed thin sheet {, i.e. the layer having its entire thickness deformed out of the plane}, e.g. corrugated, crumpled (B32B29/08 takes precedence) · CPC title

• B32B3/04

  characterised by {at least one} layer folded at the edge, e.g. over another layer {; characterised by at least one layer enveloping or enclosing a material} · CPC title