Hybrid molded and pultruded devices

Patent metadata

Field	Value
Publication number	US-12350866-B2
Application number	US-202318392746-A
Country	US
Kind code	B2
Filing date	Dec 21, 2023
Priority date	Jun 13, 2018
Publication date	Jul 8, 2025
Grant date	Jul 8, 2025

Abstract

A structural member (10) comprising: (i) a pultruded secondary member (14) including a first surface and an opposing second surface: and (ii) a molded carrier (12) overmolded onto at least one of the first and second surface of the pultruded secondary member, the molded carrier including a plurality of ribs (16); wherein the secondary member and the carrier are dissimilar materials.

First claim

What is claimed is:

1. A structural member comprising:
i) a pultruded secondary member including a first surface and an opposing second surface;
ii) a molded polyamide carrier overmolded onto at least one of the first and second surface of the pultruded secondary member, the molded carrier including a plurality of ribs;
wherein the second surface of the secondary member is substantially free of any direct contact with the carrier.

2. The structural member of claim 1 , including an adhesive material located onto at least one of the carrier and secondary member.

3. The structural member of claim 2 , wherein the adhesive material is an activatable adhesive material.

4. The structural member of claim 1 , wherein the secondary member includes a tray surface formed in the first surface, the tray surface being shaped to receive a portion of the carrier.

5. The structural member of claim 1 , wherein one or more of the carrier or secondary member includes one or more through-holes.

6. The structural member of claim 1 , wherein the plurality of ribs form one or more cavities.

7. The structural member of claim 1 , wherein the carrier is overmolded to at least partially encapsulate the secondary member.

8. The structural member of claim 1 , wherein the plurality of ribs form one or more cavities, and the one or more cavities each include a cutout that exposes the secondary member lying beneath.

9. The structural member of claim 8 , wherein the cutouts of the one or more cavities allows expansion of the secondary member beyond the carrier upon activation.

10. The structural member of claim 5 , wherein the through holes each include a reinforcement member.

11. The structural member according to claim 1 , wherein the structural member includes one or more projections extending from one or more walls of the carrier, one or more surfaces of the carrier, or both.

12. The structural member according to claim 1 , further comprising one or more fasteners that are integrally formed with the carrier.

13. The structural member according to claim 12 , wherein the one or more integrally formed fasteners are a push pin type fastener.

14. The structural member according to claim 5 , wherein an inner channel of the through holes are free of contact with the secondary member.

15. The structural member according to claim 11 , wherein the one or more through holes are located on the one or more projections.

16. The structural member according to claim 1 , wherein the ribs include one or more arcuate portions, one or more linear segments, or both.

17. The structural member according to claim 14 , wherein the through holes extend through an entire thickness of the carrier.

18. The structural member according to claim 1 , wherein the secondary member includes an expandable material.

Assignees

• Zephyros Inc

Inventors

• Richardson Henry E

Classifications

• B62D29/04

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

• B29C44/00

  Shaping by internal pressure generated in the material, e.g. swelling or foaming {; Producing porous or cellular expanded plastics articles} · CPC title

• B29C44/186

  Filling multiple cavities (B29C44/181, B29C44/182 and B29C44/188 takes precedence) · CPC title

• B29L2031/3055

  Cars · CPC title