NON-ANCHORING CORDS WITH NON-CHEMICALLY BINDING WITH THE MATRIX IN IMPACT BEAM

• US 20140217757A1
• Filed: 06/21/2012
• Published: 08/07/2014
• Est. Priority Date: 09/21/2011
• Status: Active Grant

• Current Assignee: BASF SE, NV Bekaert SA, Voestalpine Polynorm Van Niftrik BV (Polytec Holding AG)
• Original Assignee: BASF SE, NV Bekaert SA, Voestalpine Polynorm Van Niftrik BV (Polytec Holding AG)
• Inventors: Lokere, Erwin, Van Wassenhove, Veerle, Rommel, Hendrik, Gallens, Jeroen
• Granted Patent: US 9,102,288 B2
• Time in Patent Office: Days
• US Class Current: 293/120
• CPC Class Codes: B29C 70/48 and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM] , e.g. by vacuum
• CPC Class Codes: B29C 70/56 Tensioning reinforcements before or during shaping
• CPC Class Codes: B29C 70/885 with incorporated metallic wires, nets, films or plates as lost heating elements B29C35/0272, B29C61/0625
• CPC Class Codes: B29K 2995/0089 Impact strength or toughness
• CPC Class Codes: B29L 2031/3044 Bumpers
• CPC Class Codes: B60R 19/03 characterised by material, e.g. composite B60R19/18 takes precedence
• CPC Class Codes: B60R 19/18 characterised by the cross-section; Means within the bumper to absorb impact
• CPC Class Codes: B60R 2019/1813 made of metal
• CPC Class Codes: B60R 2019/1853 of reinforced plastic material
• CPC Class Codes: D03D 1/00 Woven fabrics designed to make specified articles
• CPC Class Codes: D03D 19/00 Gauze or leno-woven fabrics
• CPC Class Codes: D10B 2101/20 Metallic fibres
• CPC Class Codes: D10B 2505/02 Reinforcing materials; Prepregs
• CPC Class Codes: D10B 2505/12 Vehicles D10B2505/08 takes precedence
• CPC Class Codes: Y10T 428/249921 Web or sheet containing structurally defined element or component
• CPC Class Codes: Y10T 442/339 Metal or metal-coated strand

Abstract

An impact beam (40) comprises a polymer matrix and a reinforcing structure, the structure comprises a number of metal reinforcing cords (22) and non-metal elongated binding elements (26) or non-metal coated elongated binding elements arranged between the cords for holding the metal reinforcing cords together. Each of the metal cords has a metallic cross-sectional area Ametal, and the ratio of the metallic area Ametal to the area of the circumscribed circle (TTdcord2/4) is at least 0.60. The metal cords further have a non chemically binding with the matrix, and non-metal elongated binding elements or non-metal coated elongated binding elements have a chemical bond with said polymer matrix. By not having a mechanical interlocking and a non chemically binding with the matrix, the whole metal cord is stressed and not a local point while in the latter case the metal cord would locally break due to the very high impact forces. Therefore, the structural integrity of the impact beam as subject of the invention can be improved significantly during and after impact.

Claims

1. An impact beam comprising a polymer matrix and a reinforcing structure, said reinforcing structure comprising a number of metal reinforcing cords and non-metal elongated binding elements or non-metal coated elongated binding elements arranged between the cords for holding the metal reinforcing cords together, each of said metal reinforcing cords has a metallic cross-sectional area A_metal, the ratio φ

_c of the metallic area A_metal to the area of the circle circumscribing said metal reinforcing cord (π

d_cord²/4) is at least 0.60, said metal cords further having a non-chemical binding with said polymer matrix, wherein said non-metal elongated binding elements or non-metal coated elongated binding elements have a chemical bond with said polymer matrix.

2. An impact beam as claimed in claim 1, wherein said chemical bond is realized by bifunctional coupling agents, one functional group being responsible for the binding with the non-metal elongated binding elements or non-metal coated elongated binding elements, the other functional group reacting with the polymer.

3. An impact beam as claimed in claim 2, wherein said agents comprise silane compounds.

4. An impact beam as claimed in claim 1, wherein said polymer matrix comprises thermoplastic polymer material.

5. An impact beam as claimed in claim 4, wherein said thermoplastic polymer material is selected from the group consisting of thermoplastic elastomers, polypropylene, polyethylene, polyamide, polyethylene terephtalate, polybutylene terephtalate, polycarbonate, polyphenylene oxide, and blends of polypropylene, polyethylene, polyamide, polyethylene terephtalate, polybutylene terephtalate, polycarbonate, polyphenylene oxide.

6. An impact beam as claimed in claim 5, wherein said thermoplastic polymer material is a polypropylene- or polyamide-based thermoplastic elastomer.

7. An impact beam as claimed in claim 1, wherein said metal reinforcing cords are arranged in one or two directions.

8. An impact beam as claimed in claim 7, wherein said metal cords are arranged in only one direction, said direction being the direction of the length of the impact beam.

9. An impact beam as claimed in claim 8, wherein the distance between adjacent metal cords in said direction of the length of the impact beam is substantially equal to each other.

10. An impact beam as claimed in claim 7, wherein said metal cords provided in two directions where warp and weft are essentially perpendicular towards each other.

11. An impact beam as claimed in claim 10, wherein the distance between adjacent metal cords of said warp being substantially identical to the distance between adjacent metal cords of said weft.

12. An impact beam as claimed in claim 1, wherein said metal cords are steel cords.

13. An impact beam as claimed in claim 12, wherein said steel cord has a construction selected out of the group consisting of 3+9, 1+18, 1×

27.

14. An impact beam as claimed in claim 1 wherein said cords have an anchoring force per unit length f_a of less than 18 N/mm.

16. Use of an impact beam as in claim 1 for bumpers of vehicles or to improve the impact resistance of vehicle'"'"'s coachwork.

15. A method for providing an impact beam, said method comprising the steps of

providing metal cords and non-metal elongated binding elements or non-metal coated elongated binding elements;

providing a hybrid fabric;

bringing the hybrid fabric in an injection mold and positioning the hybrid fabric in the mold;

injecting polymer material to said hybrid fabric, providing an impact beam;

cooling the impact beam.