Multiple stage deformation reinforcement structure for impact absorption

Patent metadata

Field	Value
Publication number	US-12286158-B2
Application number	US-202217953809-A
Country	US
Kind code	B2
Filing date	Sep 27, 2022
Priority date	Jul 28, 2016
Publication date	Apr 29, 2025
Grant date	Apr 29, 2025

Abstract

A structural reinforcement for a vehicle comprising: a) a carrier having a base wall from which a plurality of projections extend, the plurality of projections including at least one first projection and at least one second projection and the at least one first projection having a height greater than a height of the at least one second projection; b) an activatable material which is heat activatable and affixed to the carrier, configured to secure the carrier in a cavity of the vehicle; wherein in event of an impact, the at least one first projection and second projection are configured to deform toward the base wall and/or in a direction of an impact load in response to the impact load; and the at least one first projection is configured to receive the impact load and deform before the at least one second projection receives the impact load and deforms.

First claim

The invention claimed is:

1. A structural reinforcement for a vehicle comprising:
a) a carrier having:
i) a first portion having a plurality of projections which form one or more first cell-like structures, wherein the plurality of projections includes a plurality of first projections and a plurality of second projections;
ii) a second portion having a second plurality of projections which form one or more second cell-like structures and which project in an opposing direction as the plurality of projections;
iii) one or more openings extending through the first portion;

b) an activatable material affixed to the carrier and disposed on the first portion, wherein the activatable material is configured to secure the carrier in a cavity of the vehicle;
wherein in event of an impact, the plurality of first projections and the plurality of second projections are configured to deform in a direction of an impact load in response to the impact load; and
wherein the plurality of first projections is configured to receive the impact load and deform before the plurality of second projections receives the impact load and deforms.

2. The structural reinforcement of claim 1 , wherein the carrier is a molded polymeric carrier.

3. The structural reinforcement of claim 1 , wherein the carrier is a single molded one-piece structure.

4. The structural reinforcement of claim 1 , wherein the activatable material is activated by heat in an automotive vehicle painting operation; and
wherein the activatable material is a structural foam, an acoustical foam, a sealant, or a combination thereof.

5. The structural reinforcement of claim 4 , wherein the activatable material expands upon activation.

6. The structural reinforcement of claim 1 , wherein the plurality of projections and the plurality of second projections include one or more ribs, posts, tabs, extensions, or any combination thereof.

7. The structural reinforcement of claim 1 , wherein the deformation of the plurality of first projections, the plurality of second projections, or both in response to the impact load is plastic deformation.

8. The structural reinforcement of claim 7 , wherein the deformation of the plurality of first projections, the plurality of second projections, or both includes a buckling of the plurality of first projections, the plurality of second projections, or both.

9. A method for making the structural reinforcement according to claim 1 comprising:
a) performing a finite element analysis to simulate the impact load;
b) generating a design of the carrier that has a structure according to claim 1 based upon results of the finite element analysis;
c) injection molding the carrier according to the design; and
d) locating the activatable material onto an external surface of the carrier.

10. The structural reinforcement of claim 1 , wherein the plurality of first projections has a height greater than a height of the plurality of second projections.

11. The structural reinforcement of claim 1 , wherein the one or more openings are located between the plurality of projections.

12. The structural reinforcement of claim 1 , wherein an additional activatable material is disposed on the second portion.

13. The structural reinforcement of claim 1 , wherein an additional activatable material is disposed on the carrier adjacent to the first portion.

14. The structural reinforcement of claim 1 , wherein the first portion is adjacent to the second portion.

15. A structural reinforcement for a vehicle comprising:
a) a carrier having:
i) a first portion having a plurality of projections which form one or more first cell-like structures, wherein the plurality of projections includes a plurality of first projections and a plurality of second projections, and wherein the plurality of first projections has a height greater than a height of the plurality of second projections;
ii) a second portion having a second plurality of projections which form one or more second cell-like structures and which project in an opposing direction as the plurality of projections;
iii) one or more openings extending through the first portion and located between the plurality of projections;

b) an activatable material affixed to the carrier and disposed on the first portion, wherein the activatable material is configured to secure the carrier in a cavity of the vehicle;
wherein in event of an impact, the plurality of first projections and the plurality of second projections are configured to deform in a direction of an impact load in response to the impact load; and
wherein the plurality of first projections is configured to receive the impact load and deform before the plurality of second projections receives the impact load and deforms.

16. The structural reinforcement of claim 15 , wherein the first portion is adjacent to the second portion.

17. The structural reinforcement of claim 16 , wherein an additional activatable material is disposed on the second portion.

18. The structural reinforcement of claim 15 , wherein an additional activatable material is disposed on the carrier adjacent to the first portion.

19. The structural reinforcement of claim 15 , wherein the activatable material expands upon activation.

20. The structural reinforcement of claim 15 , wherein the deformation of the plurality of first projections, the plurality of second projections, or both in response to the impact load is plastic deformation.

Assignees

• Zephyros Inc

Inventors

• Li Liwen
• Richardson Henry E

Classifications

• B62D29/04

  predominantly of synthetic material (working of plastics or substances in a plastic state B29) · CPC title

• B62D21/157

  for side impacts · CPC title

• B62D29/002

  a foamable synthetic material or metal being added in situ (shaping of substances in a plastic state by foaming, in general B29C44/00) · CPC title

• B62D25/04

  Door pillars {; windshield pillars} · CPC title

• B62D25/025

  Side sills thereof · CPC title