Contoured crushable composite structural members and methods for making the same

• US 6,949,282 B2
• Filed: 03/16/2001
• Issued: 09/27/2005
• Est. Priority Date: 07/07/2000
• Status: Expired due to Fees

• Current Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Original Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Inventors: Obeshaw, Dale Francis
• Primary Examiner(s): Tsoy, Elena
• Application Number:
  US09/809,778
• Publication Number:
  US 20020011047A1
• Time in Patent Office: 1,656 Days
• Field of Search: 428/131, 428/134, 428/136, 428/36.91, 428/36.1, 428/116, 138/119, 293/132, 293/133, 296/189, 527/831.1, 527/831.7, 527/941
• US Class Current: 428/131
• CPC Class Codes: A63B 60/48 with corrugated cross-section
• CPC Class Codes: B21C 37/15 Making tubes of special shape; Making tube fittings B21C37/0803, B21C37/104, B21C37/124, take precedence
• CPC Class Codes: B21C 37/154 Making multi-wall tubes
• CPC Class Codes: B29C 70/32 on a rotating mould, former or core
• CPC Class Codes: B29D 24/002 formed with structures, e.g. cores placed between two plates or sheets, e.g. partially filled totally filled B29D99/0021
• CPC Class Codes: B29D 24/004 the structure having vertical or oblique ribs
• CPC Class Codes: B29D 99/0035 rollers or cylinders having an axial length of several times the diameter, e.g. for embossing, pressing, or printing
• CPC Class Codes: B29L 2031/324 Rollers or cylinders having an axial length of several times the diameter, e.g. embossing, pressing or printing
• CPC Class Codes: B32B 1/08 Tubular products
• CPC Class Codes: B32B 15/01 all layers being exclusively metallic making layered metal workpieces by pressure cladding B23K20/22; making coatings with a metallic material characterised by its composition C23C30/00
• CPC Class Codes: B32B 15/04 comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a bituminous or tarry layer B32B11/08; next to a water-setting substance layer B32B13/06; next to a glass layer B32B17/061; next to a cellulosic plastic layer B32B23/042
• CPC Class Codes: B32B 15/08 of synthetic resin
• CPC Class Codes: B32B 27/04 as impregnant, bonding, or embedding substance not used
• CPC Class Codes: B32B 3/12 characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
• CPC Class Codes: B32B 3/28 characterised by a layer comprising a deformed thin sheet , i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled B32B29/08 takes precedence
• CPC Class Codes: B32B 3/30 characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B62D 21/00 Understructures, i.e. chassis frame on which a vehicle body may be mounted combined frame and vehicle body B62D23/00 ; characterised by the material thereof B62D29/00
• CPC Class Codes: B62D 21/09 Means for mounting load bearing surfaces
• CPC Class Codes: B65H 2701/5114 Metal sheets
• CPC Class Codes: B65H 75/10 without flanges, e.g. cop tubes
• CPC Class Codes: F16F 7/122 : characterised by corrugations, e.g. of rolled corrugated material
• CPC Class Codes: F16L 7/00 : Supporting of pipes or cables inside other pipes or sleeves, e.g. for enabling pipes or cables to be inserted or withdrawn from under roads or railways without interruption of traffic sleeves for supporting pipes, cables or protective tubing, between relatively movable points F16L3/01, fixation devices of optical cables in ducts G02B6/508, installation of electric cables H02G1/08
• CPC Class Codes: F16L 9/003 : with a rectangular cross-section ducting arrangements in air-conditioning or ventilation F24F13/02
• CPC Class Codes: F16L 9/006 : specially profiled F16L9/003 takes precedence
• CPC Class Codes: F16L 9/02 : of metal F16L9/16 - F16L9/22 take precedence
• CPC Class Codes: F16L 9/18 : Double-walled pipes; Multi-channel pipes or pipe assemblies
• CPC Class Codes: F16L 9/19 : Multi-channel pipes or pipe assemblies
• CPC Class Codes: Y10T 428/1362 : Textile, fabric, cloth, or pile containing [e.g., web, net, woven, knitted, mesh, nonwoven, matted, etc.]
• CPC Class Codes: Y10T 428/1393 : Multilayer [continuous layer]
• CPC Class Codes: Y10T 428/24149 : Honeycomb-like
• CPC Class Codes: Y10T 428/24273 : including aperture
• CPC Class Codes: Y10T 428/24298 : Noncircular aperture [e.g., slit, diamond, rectangular, etc.]
• CPC Class Codes: Y10T 428/24314 : Slit or elongated

Abstract

The present invention provides contoured crushable composite structural members and methods for making the same. The contoured structural members comprise composite materials sandwiching a support or stabilizing structure. The contoured structure can be provided by tube rolling (or roll wrapping) the composite materials and the support structure together and then, if necessary, bonding them or connecting them. The structural members are made crushable by incorporating an initiator into the structures of the members. With a contoured, crushable, and generally non-flat structure, applications for the structural members of the present invention are nearly limitless.

Claims

1. A contoured structural member, comprising:

at least one contoured inner layer comprising a composite material;

at least one contoured outer layer comprising a composite material;

at least one intermediate layer comprising a material with a cellular configuration; and

at least one initiator.

2. The structural member of claim 1, wherein the structural member has a closed configuration.

3. The structural member of claim 2, further comprising an interior region defined by an inner surface of the at least one inner layer.

4. The structural member of claim 3, wherein the interior region is hollow, partially filled, or completely filled.

5. The structural member of claim 3, wherein the at least one of the composite materials is formed from a prepreg material.

6. The structural member of claim 5, wherein the prepreg material comprises a plurality of layers.

7. The structural member of claim 6, wherein the plurality of layers have a plurality of fibers with an orientation ranging from 0 to about 90 degrees.

8. The structural member of claim 1, wherein the structural member has at least one end with the at least one initiator not located near the at least one end.

9. The structural member of claim 8, wherein the at least one initiator is located from about ½

inch to about 2 inches away from the at least one end.

10. The structural member of claim 1, wherein the cellular configuration of the at least one intermediate layer comprises a ribbed structure connecting the at least one inner layer and the art least one outer layer.

11. The structural member of claim 10, wherein the ribbed structure comprises a honeycomb core material.

12. A contoured structural member, comprising;

at least one contoured inner layer comprising a reinforced resin matrix material;

at least one contoured outer layer comprising a reinforced resin matrix material; and

at least one intermediate layer having a geometric cellular configuration; and

at least one initiator.

13. The structural member of claim 12, wherein the structural member has at least one end with the at least one initiator located from about ½

inch to about 2 inches away from the at least one end.

14. The structural member of claim 13, wherein the at least one intermediate layer has a ribbed structure connecting the at least one inner layer and the art least one outer layer.

15. A contoured structural member, comprising:

at least one contoured inner layer comprising a reinforced resin matrix material;

at least one contoured outer layer comprising a reinforced resin matrix material; and

at least one intermediate layer having a ribbed structure connecting the at least one inner layer and the art least one outer layer; and

at least one initiator.

16. The structural member of claims 15, wherein the structural member has at least one end with the at least one initiator located from about ½

inch to about 2 inches away from the at least one end.

17. A contoured structural member having at least one end, comprising:

at least one contoured inner layer comprising a reinforced resin matrix material;

at least one contoured outer layer comprising a reinforced resin matrix material; and

at least one intermediate layer having a ribbed structure connecting the at least one inner layer and the art least one outer layer; and

at least one initiator located from about ½

inch to about 2 inches away from the at least one end.

18. A contoured structural member, comprising:

at least one contoured inner layer comprising a reinforced resin matrix material;

at least one contoured outer layer comprising a reinforced resin matrix material;

at least one intermediate layer having a honeycomb structure connecting the at least one inner layer and the art least one outer layer; and

at least one initiator.

19. A closed, contoured structural member having at least one end, comprising:

at least one contoured inner layer comprising a reinforced resin matrix material;

at least one contoured outer layer comprising a reinforced resin matrix material;

at least one intermediate layer having a honeycomb structure connecting the at least one inner layer and the art least one outer layer; and

at least one initiator located from about ½

inch to about 2 inches away from the at least one end.

20. A closed, contoured structural member, comprising:

at least one contoured inner layer comprising a reinforced resin matrix material;

at least one contoured outer layer comprising a reinforced resin matrix material;

at least one intermediate layer having a honeycomb structure being substantially contiguous with the at least one inner layer and the art least one outer layer; and

at least one initiator located from about ½

inch to about 2 inches away from the at least one end.

21. A method for making a contoured structural member, comprising:

providing at least one inner layer comprising a composite material;

roll wrapping at least one intermediate layer over the at least one inner layer, the at least one intermediate layer having a cellular configuration;

providing at least one outer layer over the at least one intermediate layer, the at least one outer layer comprising a composite material;

providing at least one initiator; and

connecting the at least one inner and outer layer to the at least one intermediate layer.

22. The method of claim 21, including providing the at least one inner layer by roll wrapping the at least one inner layer over a substrate.

23. The method of claim 22, including providing the at least one outer layer by roll wrapping the at least one outer layer over the at least one intermediate layer.

24. The method of claim 23, further including removing the substrate.

25. The method of claim 24, including partially or completely filling the interior created by removing the substrate.

26. The method of claim 25, further including constraining the at least one outer layer and reacting any reactable material of the at least one inner or outer layers prior to removing the substrate.

27. The method of claim 26, including constraining the at least one outer layer by roll wrapping at least one layer of a shrink-wrap material over the at least one outer layer.

28. The method of claim 27, including removing the at least one layer of the shrink-wrap material after the reaction.

29. The method of claim 27, further including providing at least one pressure distributor over the at least one outer layer.

30. The method of claim 21, the structural member having at least one end and further providing the at east one initiator not located near the at least one end.

31. A method for making a contoured structural member, comprising:

roll wrapping at least one inner layer comprising a reinforced resin matrix material over a substrate;

roll wrapping at least one intermediate layer over the at least one inner layer, the at least one intermediate layer having a ribbed structure; and

roll wrapping at least one outer layer covering the at least one intermediate layer, the at least one outer layer comprising a reinforced resin matrix material;

providing at least one initiator;

connecting the at least one inner and outer layer to the at least one intermediate layer; and

removing the substrate.

32. A method for making a contoured structural member having at least one end, comprising:

providing at least one inner layer comprising a composite material;

roll wrapping at least one intermediate layer over the at least one inner layer, the at least one intermediate layer having a cellular configuration;

providing at least one outer layer over the at least one intermediate layer, the at least one outer layer comprising a composite material;

providing at least one initiator not located near the at least one end; and

connecting the at least one inner and outer layer to the at least one intermediate layer.

33. A contoured structural member made by the method comprising:

providing at least one inner layer comprising a composite material;

roll wrapping at least one intermediate layer over the at least one inner layer, the at least one intermediate layer having a cellular configuration;

providing at least one outer layer over the at least one intermediate layer, the at least one outer layer comprising a composite material;

providing at least one initiator; and

connecting the at least one inner and outer layer to the at least one intermediate layer.

34. A contoured structural member made by the method comprising:

roll wrapping at least one inner layer comprising a reinforced resin matrix material over a substrate;

roll wrapping at least one intermediate layer over the at least one inner layer, the at least one intermediate layer having a ribbed structure; and

roll wrapping at least one outer layer covering the at least one intermediate layer, the at least one outer layer comprising a reinforced resin matrix material;

providing at least one initiator;

connecting the at least one inner and outer layer to the at least one intermediate layer; and

removing the substrate.

35. A contoured structural member having at least one end made by the method comprising:

providing at least one inner layer comprising a composite material;

roll wrapping at least one intermediate layer over the at least one inner layer, the at least one intermediate layer having a cellular configuration;

providing at least one outer layer over the at least one intermediate layer, the at least one outer layer comprising a composite material;

providing at least one initiator not located near the at least one end; and

connecting the at least one inner and outer layer to the at least one intermediate layer.