Reinforced foam vehicle chassis

• US 8,544,585 B2
• Filed: 03/16/2010
• Issued: 10/01/2013
• Est. Priority Date: 03/19/2009
• Status: Active Grant

• Current Assignee: Lon R. Ballard
• Original Assignee: Lon R. Ballard
• Inventors: Ballard, Lon R.
• Primary Examiner(s): BROWN, DREW J
• Application Number:
  US13/256,762
• Publication Number:
  US 20120024612A1
• Time in Patent Office: 1,295 Days
• Field of Search: 180/311, 180/312, 180/89.1, 296/900, 296/901.01, 296/181.1, 296/181.2, 296/187.01, 296/187.03, 296/187.04, 296/187.05, 296/203.01
• US Class Current: 180/89.1
• CPC Class Codes: B29C 44/1214 Anchoring by foaming into a preformed part, e.g. by penetrating through holes anchoring by moulding in general B29C37/0078; outsert moulding B29C45/14344, B29C70/74
• CPC Class Codes: B29K 2105/046 with closed cells
• CPC Class Codes: B29L 2031/3002 Superstructures characterized by combining metal and plastics, i.e. hybrid parts
• CPC Class Codes: B32B 15/046 of foam
• CPC Class Codes: B32B 15/18 comprising iron or steel B32B15/011, B32B15/012 and B32B15/013 take precedence
• CPC Class Codes: B32B 15/20 comprising aluminium or copper B32B15/016 and B32B15/017 take precedence
• CPC Class Codes: B32B 17/04 bonded with or embedded in a plastic substance
• CPC Class Codes: B32B 2250/42 Alternating layers, e.g. ABAB(C), AABBAABB(C)
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer layers of natural mineral fibres or particles being impregnated in a plastic substance B32B19/02
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/0269 Aromatic polyamide fibres
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2266/0278 Polyurethane
• CPC Class Codes: B32B 2266/08 Closed cell foam
• CPC Class Codes: B32B 2307/54 Yield strength; Tensile strength
• CPC Class Codes: B32B 2307/546 Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2307/558 Impact strength, toughness
• CPC Class Codes: B32B 2307/56 Damping, energy absorption
• CPC Class Codes: B32B 2307/71 Resistive to light or to UV
• CPC Class Codes: B32B 2307/718 : Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2307/72 : Density
• CPC Class Codes: B32B 2605/00 : Vehicles
• CPC Class Codes: B32B 27/065 : of foam
• CPC Class Codes: B32B 3/12 : characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
• CPC Class Codes: B32B 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/22 : characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04
• CPC Class Codes: B32B 5/245 : another layer next to it being a foam layer
• CPC Class Codes: B32B 5/32 : at least two layers being foamed and next to each other
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B62D 29/046 : Combined superstructure and frame, i.e. monocoque constructions
• CPC Class Codes: B62D 31/003 : compact cars, e.g. city cars
• CPC Class Codes: B62D 61/08 : with single front wheel

Abstract

A light-weight vehicle component such as a vehicle chassis (100) formed from an internally reinforced rigid closed-cell foam (12). The reinforced closed-cell foam vehicle chassis (100) includes an outer layer of rigid closed-cell foam (108a), an inner layer of rigid closed-cell foam (108c), and one or more layers of reinforcing structural material (114) disposed between the inner and outer layers of foam. The reinforced closed-cell foam vehicle chassis incorporates reinforced attachment points (114a) for receiving and supporting vehicle components, such as suspension elements, steering components, a drive motor, and passenger accommodations.

Claims

1. A structural chassis component for a light-weight motorized vehicle, comprising:

a rigid closed-cell foam laminate body having an exterior surface and an interior surface, said closed-cell foam laminate body having at least an outer foam layer defining said exterior surface and an inner foam layer defining said interior surface;

at least one rigid reinforcement layer disposed between said outer foam layer and said inner foam layer of said foam laminate body; and

one or more rigid structural attachment mountings secured to said foam laminate body.

2. The vehicle component of claim 1 further including a flexible protective layer disposed on at least one of said exterior and interior surfaces of said foam laminate body.

3. The vehicle component of claim 2 wherein said flexible protective layer is UV resistant.

4. The vehicle component of claim 1 wherein said one or more rigid structural attachment mountings are coupled to said at least one rigid reinforcement layer within said closed-cell foam laminate body.

5. The vehicle component of claim 1 wherein said rigid structural attachment mountings include a steering assembly mounting, a plurality of suspension assembly mountings, and a motor mounting.

6. The vehicle component of claim 1 wherein said rigid structural attachment mountings include passenger accommodation mountings and vehicle instrumentation mountings.

7. The vehicle component of claim 1 and wherein said foam laminate body includes a nose segment and a rear segment joined by a pair of side panels and a bottom segment.

8. The improved vehicle chassis of claim 7 wherein said nose segment includes a rigid structural attachment mounting for a steered vehicle wheel assembly;

wherein said side panels each include rigid structural attachment mountings for external vehicle wheels; and

wherein said bottom panel includes rigid structural attachment mountings on an inner surface within a passenger compartment for passenger accommodations.

9. The improved vehicle chassis of claim 8 wherein at least one of said side panels further includes rigid structural attachment mountings for an external drive motor.

10. The vehicle component of claim 1 wherein said reinforced close-cell foam laminate body is buoyant.

11. The vehicle component of claim 1 wherein said rigid reinforcement layer disposed between said inner and outer foam layers is selected from a set of rigid reinforcement materials including fiberglass, epoxy impregnated fiberglass, aluminum, plastic, honey-comb coreboard, or steel.

12. The vehicle component of claim 1 wherein said foam layers, said rigid reinforcement layer, and said one or more rigid structural attachment mountings are configured to absorb energy during an impact or collision with an external object and to cushion and soften the impact to an external object during an impact or collision.

13. The vehicle component of claim 1 and wherein said inner foam layer is configured to cushion an occupant within a passenger compartment during an impact or collision with an external object.

14. The vehicle component of claim 1 wherein said one or more rigid reinforcement material layers is configured to resist buckling or breaking of said inner and outer foam layers during an impact with an external object.

15. The vehicle component of claim 1 wherein said rigid reinforcement material layer is configured to resist penetration of said reinforced closed-cell foam laminate body during an impact with an external object.

16. A light-weight motorized vehicle, comprising:

a laminated foam vehicle chassis having an exterior surface defined by at least an outer layer of closed-cell foam, an interior surface defined by an inner layer, and at least one rigid structural reinforcement material layer disposed between portions of said outer foam layer and said inner foam layer;

at least one steerable wheel coupled to a steering assembly mounted to a structural attachment mounting disposed within said laminated foam vehicle chassis;

a drive motor externally secured to a second structural attachment mounting in said laminated foam vehicle chassis;

at least one driven wheel mounted to a third structural attachment mounting on said laminated foam vehicle chassis and operatively coupled to a drive system driven by said drive motor; and

internal accommodations within a passenger compartment for at least one operator disposed within an interior volume of said laminated foam vehicle chassis.

17. The light-weight motorized vehicle of claim 16 wherein said at least one steerable wheel defines a single front wheel, and wherein said at least one driven wheel, together with at least one additional wheel transversely displaced there from about a common axis of rotation, define a pair of rear wheels.

18. The light-weight motorized vehicle of claim 16 wherein said laminated foam vehicle chassis is buoyant, and wherein said vehicle is amphibious.

19. The light-weight motorized vehicle of claim 16 wherein said laminated foam chassis is configured to absorb impact energy during a collision by deformation of said inner and outer layers of foam.

20. The light-weight motorized vehicle of claim 16 wherein said laminated foam chassis is configured to resist pass-through penetration of objects into a contained passenger compartment during a collision.