Bent aluminum foam sandwich with delamination insert

Patent metadata

Field	Value
Publication number	US-12496806-B2
Application number	US-202318163523-A
Country	US
Kind code	B2
Filing date	Feb 2, 2023
Priority date	Feb 2, 2023
Publication date	Dec 16, 2025
Grant date	Dec 16, 2025

Abstract

Aspects of the disclosure include a bent aluminum foam sandwich having a delamination insert. An exemplary bent aluminum foam sandwich can include an inner sheet, an outer sheet having a through-hole, and a core between the inner sheet and the outer sheet. A delamination insert is positioned at a bending interface between the inner sheet and the outer sheet such that sidewalls of the delamination insert are in direct contact with the core and the inner sheet. The delamination insert includes a tab positioned to extend through the through-hole.

First claim

What is claimed is:

1 . A bent aluminum foam sandwich comprising:
an inner sheet cut into a first portion and a second portion along a bending interface; an outer sheet comprising a through-hole, the outer sheet further comprising a single, continuous piece; the first portion and second portion of the inner sheet bent towards the outer sheet; a core between the inner sheet and the outer sheet; and a delamination insert comprising a first sidewall, a second sidewall, a leading edge between and in direct contact with the first sidewall and the second sidewall, and a trailing edge opposite the leading edge, the delamination insert positioned at the bending interface between the inner sheet and the outer sheet such that the first sidewall of the delamination insert is in direct contact with the core and the first portion of the inner sheet and the second sidewall of the delamination insert is in direct contact with the core and the second portion of the inner sheet, the delamination insert comprising a tab extending from the leading edge and through the through-hole.

2 . The bent aluminum foam sandwich of claim 1 , wherein the core comprises a porous foam core, the inner sheet comprises aluminum, and the outer sheet comprises aluminum.

3 . The bent aluminum foam sandwich of claim 1 , further comprising a weld positioned across the through-hole and in direct contact with the tab of the delamination insert.

4 . The bent aluminum foam sandwich of claim 1 , wherein the leading edge of the delamination insert is in direct contact with a surface of the outer sheet.

5 . The bent aluminum foam sandwich of claim 4 , wherein portions of the inner sheet and portions of the core are removed to expose the surface of the outer sheet.

6 . The bent aluminum foam sandwich of claim 5 , wherein the portions of the inner sheet and the portions of the core are removed at a 45 degree angle with respect to the surface of the outer sheet.

7 . The bent aluminum foam sandwich of claim 4 , wherein the trailing edge opposite the leading edge of the delamination insert extends beyond a surface of the inner sheet.

8 . A vehicle comprising:
a component comprising a bent aluminum foam sandwich, the bent aluminum foam sandwich comprising:
an inner sheet cut into a first portion and a second portion along a bending interface;
an outer sheet comprising a through-hole, the outer sheet further comprising a single, continuous piece;
the first portion and second portion of the inner sheet bent towards the outer sheet;
a core between the inner sheet and the outer sheet; and
a delamination insert comprising a first sidewall, a second sidewall, a leading edge between and in direct contact with the first sidewall and the second sidewall, and a trailing edge opposite the leading edge, the delamination insert positioned at the bending interface between the inner sheet and the outer sheet such that the first sidewall of the delamination insert is in direct contact with the core and the first portion of the inner sheet and the second sidewall of the delamination insert is in direct contact with the core and the second portion of the inner sheet, the delamination insert comprising a tab extending from the leading edge and through the through-hole.

9 . The vehicle of claim 8 , wherein the core comprises a porous foam core, the inner sheet comprises aluminum, and the outer sheet comprises aluminum.

10 . The vehicle of claim 8 , further comprising a weld positioned across the through-hole and in direct contact with the tab of the delamination insert.

11 . The vehicle of claim 8 , wherein the leading edge of the delamination insert is in direct contact with a surface of the outer sheet.

12 . The vehicle of claim 11 , wherein portions of the inner sheet and portions of the core are removed to expose the surface of the outer sheet.

13 . The vehicle of claim 12 , wherein the portions of the inner sheet and the portions of the core are removed at a 45 degree angle with respect to the surface of the outer sheet.

14 . The vehicle of claim 11 , wherein the trailing edge opposite the leading edge of the delamination insert extends beyond a surface of the inner sheet.

15 . A method for providing a bent aluminum foam sandwich, the method comprising:
receiving an aluminum foam sandwich comprising:
an inner sheet cut into a first portion and a second portion along a bending interface;
an outer sheet comprising a through-hole, the outer sheet further comprising a single, continuous piece; and
a core between the inner sheet and the outer sheet; and
bending the first portion and second portion of the inner sheet towards the outer sheet; positioning a delamination insert comprising a first sidewall, a second sidewall, a leading edge between and in direct contact with the first sidewall and the second sidewall, and a trailing edge opposite the leading edge at a bending interface between the inner sheet and the outer sheet such that the first sidewall of the delamination insert is in direct contact with the core and the first portion of the inner sheet and the second sidewall of the delamination insert is in direct contact with the core and the second portion of the inner sheet, the delamination insert comprising a tab extending from the leading edge and through the through-hole.

16 . The method of claim 15 , wherein the core comprises a porous foam core, the inner sheet comprises aluminum, and the outer sheet comprises aluminum.

17 . The method of claim 15 , further comprising a weld positioned across the through-hole and in direct contact with the tab of the delamination insert.

18 . The method of claim 15 , wherein the leading edge of the delamination insert is in direct contact with a surface of the outer sheet.

19 . The method of claim 18 , wherein portions of the inner sheet and portions of the core are removed to expose the surface of the outer sheet.

20 . The method of claim 19 , wherein the portions of the inner sheet and the portions of the core are removed at a 45 degree angle with respect to the surface of the outer sheet.

Assignees

• Gm Global Tech Operations Llc

Inventors

• Hodge Ethan Edward Peel
• Brown Johnny

Classifications

• B62D29/008

  predominantly of light alloys, e.g. extruded · CPC title

• B32B2266/045

  Metal · CPC title

• B32B2250/40

  Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA · CPC title

• B32B2250/03

  3 layers · CPC title

• B62D27/02

  rigid · CPC title