Reinforcing member, vehicle with structure, method for absorbing the impact of a vehicle on another vehicle, and method for producing a reinforcing member.

Abstract

REINFORCING MEMBER, VEHICLE WITH STRUCTURE, METHOD FOR ABSORBING THE IMPACT OF A VEHICLE ON ANOTHER VEHICLE AND METHOD FOR PRODUCING A REINFORCING MEMBER. The present invention relates to a reinforcing element made of a polymeric material. The present invention further relates to a vehicle comprising said reinforcing element, a method for absorbing an impact on the vehicle and a method for producing the reinforcing element.

Description

1 / 13 “REINFORCING MEMBER, VEHICLE WITH STRUCTURE, METHOD FOR ABSORBING THE IMPACT OF A VEHICLE ON A VEHICLE AND METHOD FOR PRODUCING A REINFORCING MEMBER” Field of invention

[001] The present invention relates to a reinforcing element made of a polymeric material. The present invention further relates to a vehicle comprising the reinforcing element, a method for absorbing an impact on the vehicle, and a method for producing the reinforcing element. Objective of the invention

[002] Battery casings in vehicles must be highly protected against impacts due to the risk of fire. It is therefore the objective of the present invention to provide a reinforcing element and a vehicle with improved impact resistance, particularly lateral impact resistance. Another objective is to provide an improved impact absorption method and an improved method for manufacturing reinforcing members.

[003] The objective is achieved with a reinforcing element, comprising an infinite number of reinforcing elements, each element comprising a plate and a layer with an infinite number of hollow cells, wherein the reinforcing elements are interconnected by a material bond and / or by a form and / or force fit. Brief description of the invention

[004] Disclosure on this subject matter also applies to other subjects matter and vice versa. Subject matter disclosed in relation to this embodiment of the invention may also be included in other embodiments and vice versa. Petition 870220056725, dated 06 / 29 / 2022, page 6 / 92 2 / 13

[005] The present invention relates to a reinforcing element, preferably made of a polymeric material, more preferably nylon. Each reinforcing member comprises a multiplicity, preferably two, three, four, five or more reinforcing elements, which can be supplied as semi-finished products. Each reinforcing element comprises a plate and a layer of several hollow cells, preferably identical hollow cells within a reinforcing element. The plate and the layer of hollow cells can be interconnected, for example, by gluing and / or welding and / or molding, preferably overmolding, or the semi-finished product can be supplied as a piece, for example, by molding, preferably injection molding. The plate and the layer of hollow cells can also be connected by form and / or force fitting. The plate can be a continuous flat part, whose thickness is significantly less than its length and width.However, the plate may also comprise hollow sections. The plate thickness is preferably between 0.5 - 3 mm. The plate and the hollow cell layer may be made of the same material or of different materials.

[006] According to the invention, each reinforcing element comprises a layer of hollow cells, preferably a set of hollow cells. The hollow cells within a layer are preferably identical. Each cell comprises a side wall, preferably a closed side wall, for example in the form of a ring, and has a first and a second end, which delimit the longitudinal extent of the structure. The side wall preferably has a thickness between 1 and 5 mm. The axial length of the cell between the two ends is preferably 10–50 mm. One of these ends is in contact with the plate and attached to the plate. The central axis of the cell preferably extends perpendicularly to the surface of the plate. The layer of hollow cells can be a honeycomb structure or a [missing word - likely "structure"] Petition 870220056725, dated 06 / 29 / 2022, page 7 / 92 3 / 13 Several adjacent tubes with, for example, a round, square, polygonal, or elliptical cross-section. The tubes are preferably provided as an array and may be spaced apart from each other or in contact with each other. Adjacent cells may share a common side wall.

[007] Furthermore, according to the invention, the reinforcing elements are interconnected by a material bond, for example, by gluing or welding. Alternatively or additionally, the reinforcing elements are connected by a form and / or force fitting. The connection of the reinforcing elements is preferably such that one of the two distal ends of the hollow cells of a reinforcing element is connected to the bottom of the plate of the adjacent reinforcing element. After the connection, the plates of the adjacent reinforcing elements are preferably parallel and congruent. The cell of two adjacent reinforcing elements is preferably aligned. The form and / or force fitting can be, for example, a male / female connection and / or a press fit, preferably an irreversible press fit.

[008] The bonding of the material between two adjacent reinforcing elements is preferably achieved by an adhesive layer that is provided on the board, particularly on the board surface opposite the hollow cell layer. This layer can be a continuous layer extending over the entire surface. However, the adhesive can also be applied only locally, for example, as thread(s).

[009] Two adjacent reinforcing elements within a reinforcing element may have a plate of equal or different thickness. The cell layer of two adjacent reinforcing elements within a reinforcing element may be identical or different, for example, different in shape and / or material. The reinforcing elements within a reinforcing member are preferably designed to assume different functions. By Petition 870220056725, dated 06 / 29 / 2022, page 8 / 92 4 / 13 For example, one layer can provide rigidity, while another layer absorbs energy. Depending on this function, the design of the cells, the plate and / or its material is specifically adopted.

[010] Preferably, hollow cells have a honeycomb structure.

[011] The inventive reinforcing element is preferably designed so that the longitudinal extension direction of the hollow cells is parallel to the expected load direction, while the plate surface is at an angle, preferably perpendicular, to this load direction.

[012] According to a preferred embodiment of the present invention, the reinforcing element is asymmetrical with respect to a central plane. This preferred embodiment has the advantage that the reinforcing element rotates completely and / or twists locally during a collision and thus dissipates energy.

[013] According to a preferred embodiment, the reinforcing element comprises different zones along its main extension direction. Preferably, each zone is designed to absorb energy and / or provide stiffness in a different load situation, for example, during a frontal, rear and side impact of a vehicle and / or during the lifting of a vehicle for repairs.

[014] Preferably, the reinforcing element of the invention comprises means, for example, a clamp for fixing the reinforcing element to the structure, particularly of a vehicle.

[015] The problem is also solved with a vehicle with a structure, in which the structure is reinforced by the inventive reinforcement element.

[016] Disclosure regarding this matter also applies to other matters and vice versa. The matters disclosed in relation to this Petition 870220056725, dated 06 / 29 / 2022, page 9 / 92 5 / 13 embodiments of the invention can also be included in other embodiments and vice versa.

[017] This embodiment of the present invention is directed to a vehicle, comprising a structure, preferably of steel and / or aluminum. The structure is, for example, a pillar, a beam, a rocker arm or similar. Preferably, the structure is part of and / or provided around a battery box, mainly to protect the batteries against impact, especially a side impact.

[018] Preferably, the structure is hollow and the reinforcing element is placed, preferably fixed, in the cavity of this hollow structure.

[019] Preferably, the reinforcing element is provided in the vehicle structure so that the longitudinal extension direction of the hollow cells is parallel to the reinforcement direction or impact direction. The main surface of the plate, defined by the length and width of the plate, extends at an angle, preferably perpendicular to the reinforcement direction or impact direction.

[020] Preferably, the cross-section of the reinforced structure comprises a notch. This indentation is preferably provided in a side wall, particularly in the side wall that supports the reinforcing element during a load and / or a collision. Due to this indentation, the reinforcing member twists and deforms irreversibly during an impact.

[021] The problem is also solved with a method for absorbing an impact on a vehicle, in which the reinforcing member rotates and / or twists during the impact.

[022] The disclosure regarding this matter also applies to other matters and vice versa. The matters disclosed in relation to this Petition 870220056725, dated 06 / 29 / 2022, p. 10 / 92 6 / 13 embodiments of the invention can also be included in other embodiments and vice versa.

[023] This method refers to energy absorption during an impact. According to the present invention, the reinforcing element rotates, preferably fully, or twists, preferably locally. The axis of rotation and / or twist is preferably parallel to the main extension direction of the reinforcing element and / or perpendicular to the impact direction.

[024] The reinforcing element preferably deforms plastically during impact and thus dissipates energy.

[025] The problem is also solved with a method for producing a reinforcing element, in which the reinforcing elements are glued or welded together and / or connected by a force and / or form fit.

[026] This embodiment of the present invention relates to a method for producing a reinforcing element comprising a multitude of reinforcing elements, which are supplied as semi-finished parts. These semi-finished parts each comprise a plate and a layer of hollow cells. One end delimiting the longitudinal extension of the cells of a reinforcing element is connected to the plate of the adjacent reinforcing element. The connection may be a material connection, preferably by means of an adhesive and / or by means of welding, preferably under the influence of heat and / or pressure. Alternatively or additionally, two reinforcing elements are connected by a form and / or force fitting, for example, by means of a male / female connection and / or a quick fitting.

[027] The plate and hollow cell layer of each reinforcing element can be molded as a single piece or can be prefabricated and fastened to each other. The hollow cell layer can be bonded to a Petition 870220056725, dated 06 / 29 / 2022, page 11 / 92 7 / 13 plate. Other methods for producing the reinforcing elements are, for example, pultrusion, SMC and / or BMC.

[028] The hollow cell layer can be extruded and then cut to the desired axial length of the cells and / or thickness of the hollow cell layer. Alternatively, each reinforcing element comprising the hollow cells and the plate is molded, most preferably as a single piece.

[029] The inventions are explained below in accordance with the figures. These explanations do not limit the scope of protection. The explanations apply to all embodiments of the present invention in the same way. Brief description of the figures

[030] Figure 1 shows one embodiment of a reinforcing element.

[031] Figures 2 to 3b show different views of a reinforcing member.

[032] Figure 4 represents the method for producing the inventive reinforcing member.

[033] Figure 5a - d shows the vehicle in a side impact situation.

[034] Figure 6 shows an asymmetrical reinforcing member.

[035] Figures 7 to 10 show a reinforcing member with different segments.

[036] Figures 11 and 12 show the special embodiment of the reinforcing member. Detailed description of the invention Petition 870220056725, dated 06 / 29 / 2022, page 12 / 92 8 / 13

[037] Figure 1 shows one embodiment of the reinforcing element 1. In the present case, this element comprises a plate 2, which extends throughout the length and width of the reinforcing element 1. Directly adjacent to and connected to the plate is a layer 3 of hollow cells, in the present case a honeycomb structure 17. Each cell of layer 3 has a longitudinal extension direction 18, which is delimited by two ends. One of these ends is connected to plate 2, for example, by a material connection and / or a shape and / or form fitting. One end 19 of layer 3 of hollow cells will be connected to plate 2 of an adjacent reinforcing element 1 as shown below in more detail. The longitudinal extension 18 of layer 3 is preferably 10–50 mm. The thickness of plate 2 is preferably 0.5–3 mm.The thickness of the lateral wall of the cells is preferably between 1 and 5 mm, and the internal diameter, the hollow diameter of the cells, is preferably between 4 and 15 mm. Those skilled in the art understand that, instead of a honeycomb structure, the cells 17 can be a tube with a circular or polygonal cross-section. An elliptical cross-section is also an option.

[038] Figures 2 to 3b show an embodiment of a reinforcing member 4. In the present case, the reinforcing member 4 comprises 6 reinforcing elements 1. As can be seen particularly in Figure 2, one end of the hollow cell layer 3 is connected to the plate 2 of an adjacent reinforcing element. In the present case, the reinforcing elements are connected by an adhesive layer 16, which is, in the present case, applied only locally. In Figure 2, the preferred impact direction 6 is also plotted. Preferably, the plates 2 extend perpendicularly to the impact direction 6, while the main extension direction 18 of the hollow cells 3 is parallel to the impact direction.

[039] Preferably, a layer 3 of hollow cells is the first layer, facing the impact 6, while the reinforcing element 4 is on the side Petition 870220056725, dated 06 / 29 / 2022, p. 13 / 92 9 / 13 opposite delimited by a plate 2. Now reference is made to figure 3a, in which the main element, the extension 5 of the reinforcing member 4, can be seen. Plate 2 and layer 3 of hollow cells preferably extend along the entire main extension 5. Preferably, the same applies to the widths 22 of the reinforcing element 4. Particularly in figure 3b, it can be observed that the adhesive between two adjacent reinforcing elements 1 is achieved by, in this case, three adhesive layers. Those skilled in the art understand that there may also be more or fewer adhesive layers and that the adhesive layer may also extend along the entire width 22 and length 5 of the reinforcing member 4. From all figures 2 to 3b, it can be seen that the impact 6 first strikes a layer 3 of hollow cells.

[040] The assembly process of the reinforcing element 4 is explained according to figure 4. Firstly, standard semi-finished products are provided, each comprising a plate 2 and a layer 3 of hollow cells. Plate 2 and layer 3 can be supplied as a single piece, for example, by molding. Plate 2 and layer 3 can also be, as shown, assembled to provide the semi-finished part 1. The connection between the plate and layer 3 can be a material bond and / or a form and / or strength adjustment. In the present case, the surface opposite layer 3 is provided with an adhesive layer 16, in this case a continuous adhesive layer 16. In the next step, the individual reinforcing elements 1, in this case six elements, are connected by pressing the adhesive layer 16 against the free end 19 of the hollow cell layer 3.

[041] The connection between the reinforcing elements 1, regardless of how it is made, is preferably such that it does not come loose during an impact. The same applies to the connection between the plate and the hollow cell layer 3. Petition 870220056725, dated 06 / 29 / 2022, p. 14 / 92 10 / 13

[042] Figures 5a - 5d show the inventive reinforcing member 4 mounted on the structure 7 of a vehicle. In the present case, structure 7 is a beam, as can be seen particularly in figure 5d.

[043] According to this example, the reinforcing member 4 comprises three connected reinforcing elements 1. As can be seen particularly in figure 5a, the side wall 11 of the structure 7 comprises a recess 8 in which the left side plate 2 of the reinforcing member 4 is not in contact with the side wall 11. The consequences of a side collision can be seen particularly according to figures 5a - 5c. In the embodiment according to figure 5a, the structure 7 and the reinforcing element 4 are in their original state. In figure 5b, the side impact 6 begins to compress the structure 7 and therefore the reinforcing member 4. Due to the recess 8 in the side wall 11 of the structure 7, the reinforcing member 4 is not only compressed but locally twisted, which is represented by arrow 9.This torsion, as well as all the deformation of the reinforcing member 4, dissipates so much energy that the battery case 10, which is relative to the impact 6 behind the structure 7, including the reinforcing member 4, is not deformed at all, so that the batteries, which are stored in the case, are well protected. This can be seen in Figure 5c, which shows the final state at the end of an impact. In Figure 5d, the final state after impact 6 is also plotted. It can be seen that the reinforcing element 4 is locally deformed, but that the battery case is completely intact.

[044] Figure 6 shows an alternative embodiment of the reinforcing member 4. In the present case, the reinforcing member 4 is asymmetrical with respect to one of its central planes 21, in the present case, the central plane 21 that is parallel to the impact direction 6. The asymmetry is in the present case due to an inclined surface 12. This embodiment of the reinforcing member 4 is particularly advantageous for embodiments in which the side wall 11 of the structure 7 is straight and does not have a recess 8 as shown in figure 5. Petition 870220056725, dated 06 / 29 / 2022, p. 15 / 92 11 / 13 Due to the asymmetry during an impact, reinforcing member 4 also twists as explained in Figure 5 and therefore shows enhanced energy absorption.

[045] Figures 7 to 10 show a preferred embodiment of the inventive reinforcing member. In the present case, this reinforcing element 4 comprises three sections 13-15. These sections may differ both in terms of material and in terms of the reinforcing elements 1 and / or their orientation. Section 13 is preferably designed to absorb a frontal collision, while section 14 is preferably designed to absorb a side collision and section 15 is preferably designed to improve the rigidity of the rear of a vehicle, for example, during vehicle lifting for repair. The common X-Z coordinate system used in automotive applications is shown in Figure 7. Figure 7 also lists the preferred load applications as well as the preferred martial applications. Figures 8-10 show a preferred embodiment of the reinforcing element according to Figure 7. Figure 9 shows a section of the intermediate segment 14 as well as the rear segment 15.Intermediate section 14 is the reinforcing element already explained previously, for example according to figures 2 and 3. In segment 15, in this case four reinforcing elements 1 are connected. The plates 2 of these reinforcing elements extend in this case in a horizontal plane while the longitudinal extension direction 18 of the hollow cells of layer 3 extends vertically. Due to this arrangement, forces particularly in the Z direction can be absorbed. In figure 10, segment 13 and segment 14 are represented. Regarding segment 14, reference is made to what was mentioned above. Segment 13 was designed to absorb a frontal collision. Consequently, the longitudinal extension direction 18 of the hollow cells is directed in the X direction and the plates 2 are perpendicular to the X direction to absorb a load in the X direction. Petition 870220056725, dated 06 / 29 / 2022, page 16 / 92 12 / 13

[046] Figure 11 shows a specific embodiment of the inventive reinforcing element. In the present case, the reinforcing elements 1 are not identical. From the left side, the second and fifth layers differ from the others, as the orientation of the longitudinal extension direction of the cells is different compared to the first, third, fourth, and sixth layers. In layers two and five, the longitudinal extension direction is rotated by 90°, so that this axis is in the present case parallel to the main extension direction 5 of the reinforcing member 4. Due to this design, this reinforcing member 4 can absorb impacts in different directions, for example from the side and a frontal impact. Those skilled in the art understand that the orientation, shape, size, and / or length of layer 3 may differ from reinforcing element to reinforcing element.

[047] Figure 12 shows an embodiment in which plate 2 is not a continuous solid part, but also comprises hollow structures.

[048] Reference signs: Reinforcing element, plates, hollow cell layers, reinforcing member, main extension of the reinforcing member, 4-way reinforcement, direction of impact, side impact, structure, vehicle beam structure, cavity, means of rotation, recoil rotations, battery box, side wall of the structure, side wall of the cavity. Petition 870220056725, dated 06 / 29 / 2022, page 17 / 92 13 / 13 means of rotation, inclined surface on the reinforcing member front segment of a reinforcing member middle segment of a reinforcing member rear segment of a reinforcing member connection layer, adhesive layer hollow structure, cells longitudinal extension direction one end of the structure bottom of the plate central plane width of the reinforcing member 4 X: longitudinal direction of a vehicle, extending from front to back. Y transverse direction Z vertical direction Petition 870220056725, dated 06 / 29 / 2022, p. 18 / 92

Claims

1 / 1 CLAIMS 1. Reinforcing member (4), characterized by comprising an infinite number of reinforcing elements (1), each element comprising a plate (2) and a layer (3) of an infinite number of hollow cells (17), wherein the reinforcing elements (1) are interconnected by a material connection and / or by a form and / or force fitting, wherein the reinforcing member (4) is asymmetrical with respect to the central plane (21) which is parallel to the direction of impact (6), and wherein the cross-section of the reinforced structure (7) comprises a recess (8) in the side wall (11) opposite the battery box (10) of the structure (7), such that the reinforcing member (4) is not only compressed but twisted locally during the impact (6) of the vehicle, wherein the battery box (10) is relative to the impact (6) behind the structure (7).

2. Reinforcing member (4) according to claim 1, characterized in that the hollow cells (17) are honeycomb-shaped.

3. Reinforcing member (4) according to claim 1 or 2, characterized in that one end (19) of the hollow cells of a reinforcing element (1) is connected to the bottom (20) of the plate (2) of the adjacent reinforcing element (1).

4. Reinforcing member (4), according to claim 1 or 2, characterized by comprising along its main extension direction (5) different zones (13 - 15).

5. Reinforcing member (4), according to claim 1 or 2, characterized in that the reinforcing element is plastically deformable.

6. Vehicle with structure (7), characterized in that a hollow cell (17) of the structure (7) is reinforced by a reinforcing member (4) as defined by any one of claims 1 to 5.

7. Vehicle according to claim 6, characterized in that the longitudinal extension direction (18) of the hollow cell (17) is parallel to the reinforcement direction or impact direction.

8. Vehicle according to claim 6 or 7, characterized in that the hollow cell (17) at least partially encloses a battery box (10). Petition 870240070352, dated 19 / 08 / 2024, p. 18 / 18

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