Three dimensional laminate beam structure

• US 6,272,809 B1
• Filed: 02/03/2000
• Issued: 08/14/2001
• Est. Priority Date: 09/09/1998
• Status: Expired due to Term

• Current Assignee: Henkel AG & Co KGaA
• Original Assignee: Henkel Corporation (Henkel AG & Co KGaA)
• Inventors: Wycech, Joseph S.
• Primary Examiner(s): CALLO, LAURA ANTOINETTE
• Application Number:
  US09/496,677
• Time in Patent Office: 558 Days
• Field of Search: 527/316, 527/351, 527/374, 527/381, 527/391, 527/421.3, 527/451.9, 523/094, 523/095, 523/096, 523/097, 523/099, 523/091.4, 428/36.5, 298/972, 264/46.5, 264/46.6, 264/46.7, 264/46.9, 296/187, 296/188, 296/205, 296/203.03, 280/124.134, 280/124.153
• US Class Current: 52/847
• CPC Class Codes: B29C 39/10 incorporating preformed parts or layers, e.g. casting around inserts or for coating articles coating a surface by casting in general B05D1/30, B29C39/126 takes precedence
• CPC Class Codes: B29C 44/1242 the preformed parts being concentric B29C44/1233 takes precedence
• CPC Class Codes: B29C 70/70 Completely encapsulating inserts B29C70/86 takes precedence
• CPC Class Codes: B62D 29/001 characterised by combining metal and synthetic material
• CPC Class Codes: B62D 29/002 a foamable synthetic material or metal being added in situ shaping of substances in a plastic state by foaming, in general B29C44/00
• CPC Class Codes: B62D 65/00 Designing, manufacturing, e.g. assembling, facilitating disassembly, or structurally modifying motor vehicles or trailers, not otherwise provided for
• CPC Class Codes: Y10T 29/49622 Vehicular structural member making

Abstract

A three-dimensional laminate beam is formed by inserting a preformed foam core insert within a hydra-formed metal section having curved three-dimensional geometry. A reinforcing polymer is pumped in and around the foam core insert so as to be adjacent the inside wall of the shell. The polymer bonds to the inside wall of the shell upon the polymer being cured.

Claims

1. A three dimensional laminate beam structure comprising an outer shell having inside walls and an open space between said walls, said shell tapering inwardly in thickness over a portion of its length, said shell having a curved three-dimensional geometry from end to end, an insert having a core mounted within said shell spaced from at least one of said inside walls, a reinforcing polymer within said shell, and said polymer being disposed against said core insert and bonded to said core and to said inside wall of said shell.

2. The beam of claim 1 wherein said core is made of a lightweight foam.

3. The beam of claim 2 wherein said shell is made of a metal material being of uniform shape along a portion of its length.

4. The beam of claim 3 wherein said shell is a hydra-formed metal section.

5. The beam of claim 4 wherein said beam comprises a vehicle control arm assembly.

6. The beam of claim 2 wherein said polymer is an expandable structural foam.

7. The beam of claim 2 wherein said polymer is a non-expandable structural foam.

8. The beam of claim 2 wherein said polymer is heat curable.

9. The beam of claim 2 wherein said polymer is ambient temperature curable.

10. The beam of claim 1 including locating structure extending outwardly from said core and fitting snugly against said inside wall of said shell to properly locate said insert in said shell.

11. The beam of claim 10 wherein said locating structure includes an end flange on one end of said core, and said core being spaced from said inside wall of said shell to create a chamber completely peripherally around said core.

12. The beam of said claim 11 wherein said flange is a first flange, said locating structure including a second end flange mounted outwardly from said core remote from said first flange, and said second flange fitting snugly against said inside wall of said shell whereby said first flange and said second flange comprise end walls for said chamber.

13. The beam of claim 12 including a hole in a side wall of said shell to permit said polymer to be inserted into said chamber through said hole.

14. The beam of claim 13 including a passageway in said core in line with said hole in said shell.

15. The beam of claim 14 wherein there are two of said holes in said shell and two of said aligned passageways in said core.

16. The beam of claim 14 including a boss connected to one of said flanges, and extending outwardly of said core.

17. The beam of claim 14 wherein said tapered portion of said shell merges with the remaining portion of said shell which is of uniform cross-section, and said core having a shape which conforms to the shape of said outwardly disposed shell but is of smaller size to create said chamber therebetween.

18. A reinforcement insert for insertion into the cavity of a structural member to reinforce the structural member, said insert having an elongated core made of a lightweight material, said core being curved over its length, a portion of said core tapering in its thickness inwardly from one end of said core, and locating structure extending outwardly from said core for locating said insert in a predetermined position within the structural member.

19. The insert of claim 18 wherein said core is made of a lightweight foam.

20. The insert of claim 19 including locating structure extending outwardly from said core for fitting snugly against the inside wall of the structural member to properly place said insert within the structural member.

21. The insert of claim 20 wherein said locating structure includes a flange extending outwardly from said core at one end of said core.

22. The insert of claim 21 wherein said flange is a first flange, and a second flange extending outwardly from said core at an end of said core opposite said first flange.

23. The insert of claim 22 including at least one passageway extending completely through said core.

24. The insert of claim 23 wherein said tapered portion of said core merges with the remaining portion of said core which is of uniform cross-sectional thickness.

25. The insert of claim 24 including a boss secured to one of said flanges and extending outwardly from said core.

26. A method of forming a three-dimensional laminate beam comprising the steps of inserting a pre-formed insert within a hollow shell with the insert having an elongated lightweight core spaced from at least one inside wall of the shell and with the shell tapering inwardly in thickness over a portion of its length and with the shell being curved to form a curved three-dimensional geometry from end to end, pumping a reinforcing polymer in and around the core, and curing the polymer to cause the polymer to bond to the inside wall of the shell and to the core.

27. The method of claim 26 including locating the insert within the hollow shell by means of locating structure extending outwardly from the core with the locating structure fitting snugly against the inside wall of the shell.

28. The method of claim 27 wherein the core conforms in shape to the shape of the inside wall of the shell but is of smaller dimension to create a peripheral chamber around the core.

29. The method of claim 28 including pumping the polymer into the chamber through a hole in the wall of the shell.

30. The method of claim 29 wherein the polymer is pumped through the hole in the shell and flows through a passageway in the core aligned with the hole in the shell, and wherein the polymer is of multi-component form.

31. The method of claim 30 wherein the shell an the core each include a tapered portion which merges with a remaining portion that is of uniform cross-sectional thickness and the core including an end flange at the tapered end of the core and an end flange at the uniform thickness end of the core with each of the flanges fitting snugly against the inside wall of the shell.

32. The method of claim 26 wherein the shell is made of a hydra-formed metal.

33. The method of claim 26 wherein the resulting beam is a vehicle control arm assembly.

34. The method of claim 26 wherein the resulting beam is a vehicle component.

35. The method of claim 26 wherein the polymer is heat cured.

36. The method of claim 26 wherein the polymer expands upon curing.

37. The method of claim 26 wherein the polymer is cured at ambient temperatures.