Hybrid Molded & Pultruded Devices

Patent metadata

Field	Value
Publication number	US-2021237377-A1
Application number	US-201916972145-A
Country	US
Kind code	A1
Filing date	Jun 13, 2019
Priority date	Jun 13, 2018
Publication date	Aug 5, 2021
Grant date	—

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

1 . A structural member comprising:
i) a pultruded secondary member including a first surface and an opposing second surface; ii) a molded 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; and iii) an adhesive material located in contact with one or more of the secondary member or molded carrier; wherein the secondary member and the carrier are dissimilar materials.

2 . (canceled)

3 . The structural member of claim 1 , 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 the second surface of the secondary member is substantially free of any direct contact with the carrier.

6 . The structural member of claim 3 , wherein one or more of the carrier or secondary member includes one or more through-holes.

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

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

9 . The structural member of claim 3 , 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.

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

11 . The structural member of claim 6 , wherein the through holes each include a reinforcement member.

12 . 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.

13 . The structural member according to claim 3 , further comprising one or more integrally formed fasteners.

14 . (canceled)

15 . The structural member according to claim 6 , wherein an inner channel of the through holes are free of contact with the secondary member.

16 . The structural member according to claim 12 , wherein the one or more through holes are located on the one or more projections.

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

18 . The structural member according to claim 15 , wherein the through holes extend through an entire thickness of the carrier.

19 . (canceled)

20 . The structural member according to claim 1 , wherein the structural member is configured to attach to a transmission of a vehicle, one or more body rails of a vehicle, or both.

21 . The structural member according to claim 1 , wherein the carrier member comprises a polyamide material.

22 . The structural member according to claim 1 , wherein the secondary member comprises a polyurethane material.

23 . The structural member according to any of claims 1 through 22 , wherein the adhesive material is an epoxy-based adhesive material.

24 - 32 . (canceled)

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

• B29C70/52 Primary

  Pultrusion, i.e. forming and compressing by continuously pulling through a die · CPC title

• B29C44/04 Primary

  consisting of at least two parts of chemically or physically different materials, e.g. having different densities · CPC title

• B29L2031/3055

  Cars · CPC title

• B29L2031/3005

  Body finishings · CPC title