Reinforced impact beam

• US 6,883,843 B2
• Filed: 03/07/2003
• Issued: 04/26/2005
• Est. Priority Date: 03/08/2002
• Status: Expired due to Term

• Current Assignee: NV Bekaert SA, Voestalpine Polynorm BV (Voestalpine AG)
• Original Assignee: NV Bekaert SA, Polynorm N. V.
• Inventors: Dekeyser, Willem, Corscadden, Paul, Van Damme, Peter A.M.
• Primary Examiner(s): Patel, Kiran B.
• Application Number:
  US10/383,259
• Publication Number:
  US 20030184099A1
• Time in Patent Office: 781 Days
• Field of Search: 293/120, 293/121, 293/122, 293/102, 156/142, 156/307.7, 156/140, 152/540, 152/527, 152/555, 152/451, 572/58, 573/11, 572/37, 474/265, 474/260, 474/263, 428/591, 428/375, 428/107, 428/294.1, 428/515, 428/297.4, 428/300.7, 428/98, 428/64.1, 428/35.7, 427/240, 527/861.1, 198/847, 512/95, 442/8, 442/316
• US Class Current: 293/120
• CPC Class Codes: B29C 70/46 using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
• CPC Class Codes: B29C 70/52 Pultrusion, i.e. forming and compressing by continuously pulling through a die
• 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 19/18 characterised by the cross-section; Means within the bumper to absorb impact
• CPC Class Codes: B60R 2019/1806 Structural beams therefor, e.g. shock-absorbing bumper beams made of cellular materials B60R19/22
• CPC Class Codes: B60R 2019/1853 of reinforced plastic material
• CPC Class Codes: Y10T 29/49622 Vehicular structural member making
• CPC Class Codes: Y10T 29/4998 Combined manufacture including applying or shaping of fluent material
• CPC Class Codes: Y10T 29/49984 and casting

Abstract

An impact beam having a polymer matrix and a metal reinforcing structure, the metal reinforcing structure including metal cords that can be made from metal elements having a diameter of 100 μm or more. The polymer matrix can include a thermoplastic material and/or a fiber material, and the metal can be steel, and the metal cords can be parallel to each other. The polymer matrix can include two or more layers that can be made from the same or different material, one of which can be positioned around the surface of the metal cords and can have a mechanical bond with the cord. The invention also includes a method of making the impact beam.

Claims

1. An impact beam comprising:

a polymer matrix and a metal reinforcing structure for impact reinforcement, said metal reinforcing structure consisting of metal cords, wherein said metal cords are bonded to said polymer matrix so that a load can be transmitted directly between the polymer matrix and the metal cords.

2. The impact beam as in claim 1, wherein said metal cords are essentially parallel to each other.

3. The impact beam as in claim 2, said metal cords comprising metal elements having a diameter of equal to or more than 100 μ

m.

4. The impact beam as in claim 2, wherein said metal cords have an optical diameter of more than 200 μ

m.

5. The impact beam as in claim 2, wherein said polymer matrix comprises thermoplastic polymer material.

6. The impact beam as in claim 2, wherein said polymer matrix comprises polymer material 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, and polyphenylene oxide.

7. The impact beams as in claim 6, wherein said polymer material is a polyamide- or polyolefin-based thermoplastic elastomer.

8. The impact beam as in claim 2, wherein said polymer matrix comprises thermoset polymer material.

9. The impact beam as in claim 8, wherein said polymer matrix comprises polymer material selected from the group consisting of unsaturated polyesters, epoxies, vinyl-esters and phenolic resins.

10. The impact beam as in claim 2, wherein said metal cords are steel cords.

11. The impact beam as in claim 2, wherein said metal cords are arranged in one or more planes, said planes being essentially parallel to each other.

12. The impact beam as in claim 2, wherein said polymer matrix comprises at least two layers, a first layer being present around a surface of said metal cords, and a second layer being present around said first layer.

13. The impact beam as in claim 12, wherein said first layer is made out of polymer material 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, and polyphenylene oxide.

14. The impact beam as in claim 12, wherein said second layer is made out of polymer material 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, and polyphenylene oxide.

15. The impact beam as in claim 2, wherein said metal cords have a mechanical bond with said polymer matrix.

16. The impact beam as in claim 2, wherein said metal cords have a chemical bond with said polymer matrix.

17. The impact beam as in claim 2, wherein said polymer matrix further comprises glass- or C-fibers, polymeric fibers and/or mineral fillers.

18. Use of the impact beam as in claim 2 for support of bumpers of vehicles or to improve the impact resistance of a vehicle'"'"'s coachwork.