Reinforcement structure

Patent metadata

Field	Value
Publication number	US-2022169317-A1
Application number	US-202017599267-A
Country	US
Kind code	A1
Filing date	Mar 12, 2020
Priority date	Apr 2, 2019
Publication date	Jun 2, 2022
Grant date	—

Abstract

A structural member ( 10 ) comprising: (i) a first carrier ( 12 A) and a second carrier ( 12 B), each carrier including a plurality of interconnecting ribs ( 16 ), each carrier further including one or more projections ( 28 ) extending from exterior walls ( 30 ) of each carrier; (ii) one or more secondary members ( 14 ) secured to one or more surfaces of each carrier; and (iii) an adhesive material ( 32 ) disposed on the first carrier ( 12 A), the second carrier ( 12 B), or both, wherein the first carrier ( 12 A) and the second carrier ( 12 B) are bonded to each other via the adhesive material ( 32 ).

First claim

1 . A structural member comprising:
i) a first carrier and a second carrier, each carrier including a plurality of interconnecting ribs, each carrier further including one or more projections extending from exterior walls of each carrier; ii) one or more secondary members secured to one or more surfaces of each carrier; and iii) an adhesive material disposed on the first carrier, the second carrier, or both, wherein the first carrier and the second carrier are bonded to each other via the adhesive material.

2 . The structural member according to claim 1 , wherein the adhesive material is cured at room temperature to bond the first carrier and the second carrier.

3 . The structural member according to claim 2 , wherein the carriers and the one or more secondary members are different materials.

4 . The structural member according to claim 3 , wherein the carriers are a polyamide material and the one or more secondary members are a carbon fiber reinforced thermoplastic.

5 . The structural member according to claim 1 , wherein the adhesive material is disposed on the one or more projections and the one or more projections of the first carrier and the second carrier abut one another to form the bond.

6 . The structural member according to claim 1 , wherein one or more mechanical fasteners temporarily connect the first carrier and the second carrier together during a curing time of the adhesive material.

7 . The structural member according to claim 6 , wherein one or more through holes of the first carrier and one or more through holes of the second carrier are aligned so that the mechanical fasteners extend through the aligned one or more through holes, and after curing of the adhesive material to bond the first carrier and the second carrier, the one or more through holes of the first carrier and the one or more through holes of the second carrier are configured to mount the structural member to one or more structures of a vehicle.

8 . The structural member according to claim 1 , wherein after bonding, the first carrier and the second carrier form a clamshell shape and the one or more secondary members are positioned within the clamshell shape.

9 . The structural member according t claim 1 , wherein the first carrier and the second carrier are overmolded around one or more surfaces of the one or more secondary members.

10 . The structural member according to claim 8 , wherein the curing time of the adhesive material is unaffected by heating the adhesive material to a temperature of about 204° C. or less.

11 . The structural member according to claim 8 , wherein the plurality of interconnecting ribs form one or more cavities within the first carrier, the second carrier, or both.

12 . The structural member according to claim 11 , wherein the one or more cavities include a cutout near the one or more surfaces of the first carrier, the second carrier, or both that abuts the one or more secondary members.

13 . The structural member according to claim 7 , wherein the one or more through holes of the first carrier and the one or more through holes of the second carrier include a reinforcement member.

14 . The structural member according to claim 1 , further comprising one or more monolithically formed fasteners projecting from the one or more projections.

15 . The structural member according to claim 14 , wherein the one or more monolithically formed fasteners are a push pin type fastener.

16 . The structural member according to claim 1 , wherein the one or more secondary members extend along one or more outer walls of the first carrier, the second carrier, or both.

17 . The structural member according to claim 1 , wherein the first carrier and the second carrier are extruded or pultruded nylon material and the one or more secondary members are a molded carbon fiber reinforced thermoplastic.

18 . The structural member according to claim 17 , wherein the carbon fiber reinforced thermoplastic includes an epoxy resin, and the epoxy resin bonds to the extruded nylon material so that the first carrier and the second carrier are bonded to the one or more secondary members.

19 .- 22 . (canceled)

23 . The structural member according to claim 12 , wherein the cutouts of the one or more cavities expose the secondary member.

24 .- 30 . (canceled)

31 . The structural member according to claim 1 , wherein the adhesive is disposed on both the first carrier and the second carrier, and the adhesive disposed on the first carrier is free of contact with the adhesive disposed on the second carrier when the first carrier and the second carrier are bonded to each other.

32 .- 43 . (canceled)

Assignees

• Zephyros Inc

Inventors

• Richardson Henry E

Classifications

• B62D29/048

  Connections therefor, e.g. joints (B62D29/045 takes precedence) · CPC title

• B29C45/14

  incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles {(B29C45/1671 takes precedence)} · CPC title

• B29C70/52

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

• B29C66/712

  the composition of one of the parts to be joined being different from the composition of the other part · CPC title

• B29C66/1312

  Single flange to flange joints, the parts to be joined being rigid (the parts to be joined being flexible B29C66/133) · CPC title