Method and apparatus for overmolding fiber-reinforced polymer components

Abstract

The present invention relates to a method and apparatus for overmolding fiber-reinforced polymer components, and in particular to a method for manufacturing a hollow overmolded polymer article, comprising: placing a hollow polymer structure (10) in a mold (100); supporting the inner surface of the hollow polymer structure; arranging a fibrous polymer material (12) in the mold adjacent to the outer surface of the hollow polymer structure; overmolding the fibrous polymer material onto the outer surface of the hollow polymer structure; opening the mold; and removing the hollow overmolded polymer article comprising the fibrous polymer material overmolded on the hollow polymer structure.

Description

[0001] This application is a divisional application of Chinese patent application No. 201580033185.9, whose application date is July 1, 2015 and whose invention name is “Method and device for overmolding fiber-reinforced polymer components”. Technical Field

[0002] The present disclosure relates to fiber reinforced polymer materials overmolded onto polymer inserts to form closed cross-section geometries for use as structural reinforcement components and methods of making the same. Specifically, closed cross-section reinforcement structures for vehicle structural components such as lift gates and methods of making the same are disclosed herein. Background Art

[0003] Structural components for vehicles such as front-end modules and liftgates can be loaded with torsional forces generated by forces acting at different locations. To accommodate this demand, it is desirable to have high bending stiffness in such structural components. The liftgate is a large component of the vehicle body and rotates substantially around the hinge when it is opened or closed. The liftgate is provided to open or close an opening portion formed at the rear of a hatchback type passenger vehicle, etc. Due to the stress levels from repeated opening and closing of the liftgate and the size of the liftgate, ribs or steel inserts may be used to ensure proper operation and structural stability. Other attempts to increase stiffness and torsional stiffness include increasing the thickness of the panel. However, increasing the thickness of the panel and / or adding ribs to increase the rigidity of the liftgate also increases the overall weight of the liftgate, which can negatively affect the fuel efficiency of the vehicle. In addition, the use of reinforcements such as ribs may affect the ability to efficiently pass wires, cables, etc. through the liftgate. In addition, ribs and other reinforcements negatively affect the aesthetic quality of the liftgate because such features may leave visible defects on the panel, thus requiring the installation of additional panels to provide a complete appearance. The use of steel or other materials in conjunction with a plastic liftgate may also increase the manufacturing time and cost of producing the liftgate or vehicle assembly.

[0004] Since the weight of the vehicle body has an impact on the fuel consumption of the vehicle, attempts have been made to produce liftgates from lightweight materials such as polymer materials in an effort to reduce the overall weight of the vehicle. The use of polymer materials reduces the overall weight, but in some applications may not accommodate the stresses and strains placed on the liftgate. As an example, the liftgate may desirably flex. This may displease the consumer. Even worse, such flex may not adequately resist deformation in a collision.

[0005] For some applications, techniques such as injection molding and / or injection compression molding, such as using a given pulling direction and slider, cannot provide the desired and / or sufficient torsional stiffness for the structural component. Other techniques such as gas injection molding and water injection molding do not provide the necessary control across the wall thickness. In addition, the use of collapsible cores and sliders may include components that move during the molding process, which leads to deviations in the expected wall thickness. Therefore, attempts have been made to use metal inserts to provide surfaces for molding polymer structural components. However, metal inserts increase weight and negatively affect the fuel economy of the vehicle. Moreover, past attempts to manufacture fiber-reinforced components have shown many manufacturing defects, including variable wall thickness and difficulty in reproducing wall thickness. For example, long glass fiber reinforced plastics may suffer from the disadvantage of "fiber foaming" inside the component (e.g., where the fiber-reinforced plastic contacts the load-bearing slider, core or metal insert).

[0006] EP 0 492 129 A1 relates to a multilayer plastic tube and a method for producing the same. The method for producing a multilayer tube uses a spacer (13) to prevent a hollow plastic core (11) placed in a mold cavity from deforming when molten plastic material is provided under pressure into the mold cavity.

[0007] Therefore, there is a need for lightweight polymer components comprising fiber reinforced polymers having controllable and reproducible wall thicknesses. Summary of the invention

[0008] Disclosed herein are closed cross-section geometry reinforcement components made of a fiber reinforced polymer material overmolded onto a polymer insert and methods for making the same.

[0009] A method for making a hollow overmolded polymer article comprises: placing a hollow polymer structure in a mold; supporting the inner surface of the hollow polymer structure; setting a fibrous polymer material into the mold adjacent to the outer surface of the hollow polymer structure; overmolding the fibrous polymer material onto the outer surface of the hollow polymer structure; opening the mold; and removing the hollow overmolded polymer article comprising the fibrous polymer material overmolded on the hollow polymer structure.

[0010] A method for producing an overmolded polymer article comprises: placing a prefabricated hollow polymer component in a mold; wherein the hollow polymer component is open at two ends; plugging the two ends, wherein one plug is connected to a pressurizing device; applying internal pressure to the hollow polymer component; and overmolding the hollow polymer component with a fibrous polymer.

[0011] A hollow overmolded polymer article comprising: a fibrous polymer overmolded on a hollow polymer structure; wherein the hollow polymer structure comprises a wall thickness less than or equal to 0.5 mm.

[0012] The above described and other features are exemplified by the following figures and detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Reference is now made to the drawings, which are exemplary embodiments, and in which like elements are numbered alike.

[0014] Figure 1 is a cross-sectional side view of a molding apparatus equipped with a pressurizing device to support a hollow polymer structure.

[0015] Figure 2 is a cross-sectional side view of a molding apparatus equipped with an insert to support a hollow polymer structure.

[0016] Figure 3 is a cross-sectional side view of a molding apparatus equipped with slides to support a hollow polymer structure.

[0017] Figure 4 is a cross-sectional view of a hollow overmolded polymer article.

[0018] Figure 5 is a flow chart of a method for making a hollow overmolded polymer article.

[0019] Figure 6 is a flow chart of a method for making a hollow overmolded polymer article. DETAILED DESCRIPTION

[0020] Disclosed herein are structural reinforcement components and methods of producing structural reinforcement components comprising polymer inserts overmolded with fiber reinforcement materials, resulting in increased bending and torsional stiffness and consistent, reproducible wall thickness. Advantageous results obtained herein, for example, low mass, high strength polymer components can be achieved by using polymer inserts having thin hollow sections overmolded with fiber reinforcement materials to form closed cross-sectional geometries.

[0021] Hollow overmolded polymer articles can include a fibrous polymer overmolded on a hollow polymer structure or insert. For example, the hollow polymer structure or insert can have a closed cross-sectional geometry. Therefore, when overmolded with a fibrous polymer material, the resulting article can have a closed cross-sectional geometry. The hollow polymer structure can be prefabricated and placed in a mold before overmolding with the fibrous polymer material. The hollow polymer structure can include any closed cross-sectional geometry. For example, the hollow polymer can have a cross-sectional shape that is polygonal, circular, elliptical, and a combination of at least one of the above. The hollow polymer structure can have a thickness less than or equal to 0.5 millimeters (mm).

[0022] The fiber reinforcement material (also referred to as fiber material) overmolded on the hollow polymer structure can form the outside of the molded product and can take any shape and is not limited to the exact cross-sectional shape of the hollow polymer structure. For example, the hollow structure can have a square cross section, and the fiber reinforcement material can be overmolded with a rectangular cross section or a circular cross section. The fiber reinforced part of the product can have a thickness greater than the thickness of the hollow polymer structure. For example, the fiber reinforced part can have a thickness greater than or equal to 150% of the thickness of the hollow polymer structure. The fiber reinforced part can have a thickness greater than or equal to 200% of the thickness of the hollow polymer structure. When the cross-sectional shape is the same as the hollow polymer structure, the thickness of the fiber material overmolded on the hollow polymer structure can vary less than or equal to 2% at any point on the product. However, when the cross-sectional shape of the overmolded fibrous material is different from the hollow polymer structure (for example, a rectangular overmolded cross section on a hollow polymer structure with a square cross section), the thickness of the fibrous material can vary. Therefore, a consistent thickness can be obtained.

[0023] The method for making a hollow overmolded polymer article may include placing a hollow polymer structure in a mold. The hollow portion of the hollow polymer structure may be pressurized. For example, the end of the hollow polymer structure may be plugged and a pressurized fluid or gas source may be connected to one of the plugs. Pressurized fluid or gas may be introduced into the hollow space. Pressurized fluid or gas may apply a pressure greater than or equal to the inner surface of a molding device on the inner surface of the hollow polymer structure. Pressurized fluid or gas may be at a temperature lower than the mold surface and / or the polymer structure. This molding device with a pressurized fluid (e.g., water or gas) source may include any suitable molding device that can be connected to a pressurizing device.

[0024] In an alternative, one or more inserts may be introduced into the hollow space within the hollow polymer structure. The insert may be a slide configured to be removed after the molding process is complete. The insert may be a single piece of material configured to be removed when the molding process is complete. The insert may be metal, ceramic, or any material suitable for withstanding molding pressures. The insert may contact the interior of the hollow polymer structure. The insert may include a portion that does not contact the interior of the hollow polymer structure. In other words, the insert may include an outer surface that does not match the inner surface of the hollow polymer structure.

[0025] The fibrous polymer material may be disposed in a mold adjacent to the outer surface of the hollow polymer structure. For example, the fibrous polymer material may be introduced by injection molding.

[0026] The mold can be closed to overmold the fibrous polymer material onto the outer surface of the hollow polymer structure. The mold can be opened and the hollow overmolded polymer article comprising the fibrous polymer material overmolded on the hollow polymer structure can be removed.

[0027] The overmolded polymer article can be used in vehicle components. As used herein, the term "vehicle component" can refer to lift gates, door modules, front end modules, and other components such as (but not limited to) dashboard trays, bumper cladding of vehicle structures. For example, the overmolded polymer article can be used as a reinforcement component for a lift gate.

[0028] Examples of polymer materials for thin hollow structures include thermoplastic materials and combinations of thermoplastic materials with elastomeric materials and / or thermosetting materials. Possible thermoplastic materials include polybutylene terephthalate (PBT); acrylonitrile butadiene styrene (ABS); polycarbonate (LEXAN TM and LEXAN TM EXL resin, commercially available from SABIC Innovative Plastics); polycarbonate / PBT blends; polycarbonate / ABS blends; copolycarbonate-polyester; acrylic-styrene-acrylonitrile (ASA); acrylonitrile-(ethylene-polypropylene diamine-modified)-styrene (AES); phenylene ether resins; polyphenylene ether / polyamide blends (NORYL GTX TM resin, commercially available from SABIC Innovative Plastics); blends of polycarbonate / polyethylene terephthalate (PET) / PBT; polybutylene terephthalate and an impact modifier (XENOY TMResins, commercially available from SABIC Innovative Plastics); polyamides; polyphenylene sulfide resins; polyvinyl chloride PVC; high impact polystyrene (HIPS); low / high density polyethylene (L / HDPE); polypropylene (PP); expanded polypropylene (EPP); and thermoplastic olefins (TPO) and combinations including at least one of the foregoing. The fibrous polymer material for overmolding the hollow polymer structure may include any of the aforementioned polymer materials that can be used in a reinforced composite polymer material incorporating a reinforcing material. As used herein, the reinforced composite polymer may include polymers and reinforcing materials, such as fibers (continuous, chopped, woven, etc.) formed from aramid, carbon, basalt, glass, plastic, metal (e.g., steel, aluminum, magnesium), quartz, boron, cellulose, liquid crystal polymers, high toughness polymers (e.g., polypropylene, polyethylene, poly(hexamethylene-6-lactam), poly[imino(1,6-dioxyhexamethylene)iminohexamethylene]), thermoplastic polymer fibers, thermosetting polymer fibers, or natural fibers and combinations including at least one of the foregoing. The high toughness polymer may be poly[imino(1,6-dioxyhexamethylene)iminohexamethylene]. An exemplary fiber-filled resin is STAMAX TM Resin, which is a long glass fiber filled polypropylene resin also commercially available from SABIC Innovative Plastics. Another exemplary fiber material may include a long fiber reinforced thermoplastic (VERTON TM Resin, commercially available from SABIC Innovative Plastics).

[0029] The fiber polymer material may contain 10 to 90 wt.% of fiber and 90 to 10 wt.% of polymer material. The fiber polymer material may contain 25 to 75 wt.% of fiber and 75 to 25 wt.% of polymer material. The fiber used may include long fibers, for example, fibers having an aspect ratio (length / diameter) greater than or equal to 10. The fiber may include an aspect ratio greater than or equal to 50. The fiber may include an aspect ratio of 50 to 500. The fiber may include an aspect ratio of 80 to 400. For example, the diameter of the long fiber may be in the range of 5 to 35 microns (μm). The diameter of the long fiber may be 10 to 20 μm. The fiber may have, for example, a length greater than or equal to 0.4 mm, for example, 0.4 mm to 30 mm or longer. The fiber may include a length greater than or equal to 1 mm. The fiber may include a length greater than or equal to 2 mm.

[0030] The fiber polymer material can be less than or equal to 1.5 g / cm 3 The material of the hollow polymer structure may have a density less than or equal to 1.5 g / cm 3 density.

[0031] A more comprehensive understanding of the components, methods, and devices disclosed herein may be obtained with reference to the accompanying drawings. These drawings (also referred to herein as "figures") are schematic diagrams based on convenience and ease of demonstrating the present disclosure, and are therefore not intended to indicate the relative size and dimensions of the device or its components and / or to define or limit the scope of the exemplary embodiments. Although specific terms are used in the following description for clarity, these terms are only intended to refer to the specific structure of the embodiments selected for the illustration of the drawings, and are not intended to define or limit the scope of the present disclosure. In the following drawings and the following description, it should be understood that the same numerals refer to components of the same function.

[0032] Figure 1 A molding device 100 including an upper mold portion 1 and a lower mold portion 2 is shown. A hollow polymer structure (assembly) 10 is placed in the molding device 100. The ends of the hollow polymer structure 10 can be plugged with one or more plugs 16. A pressurizing device 18 can be connected to the plug 16 and provide internal pressure to the hollow space 12 within the hollow polymer structure 10. For example, the pressurizing device 18 can deliver a pressurized fluid (e.g., water or gas) 22 to the hollow space 12 at a pressure equal to or greater than the pressure provided by the upper mold 1 and the lower mold 2. A fiber material 20 can be disposed adjacent to the outer surface of the hollow polymer structure 10 and overmolded on the hollow polymer structure 10. For example, the fiber material 20 can be injected into the mold device. When the molding device is opened, the pressurizing device 18 and the plug 16 can be removed from the ends of the hollow polymer structure 10 and the overmolded polymer article can be removed from the molding device 100.

[0033] like Figure 2 As shown, a metal insert 26 can be inserted into the hollow space 12 of the hollow polymer structure 10. The metal insert 26 has sufficient strength to withstand the pressure from the upper mold 1 and the lower mold 2 during the molding process without deformation. Therefore, the metal insert 26 provides an internal support for the hollow polymer structure 10 that is stronger than or equal to the molding pressure. The fiber material 20 can be disposed adjacent to the hollow polymer structure 10 and overmolded on the hollow polymer structure 10. When the mold apparatus 200 is opened, the metal insert 26 can be removed from the hollow space 12 and the overmolded polymer article can be removed from the molding apparatus 200.

[0034] like Figure 3As shown, a slider 24 can be inserted into the hollow space 12 of the hollow polymer structure 10. The slider 24 can have sufficient strength to withstand the pressure from the upper mold 1 and the lower mold 2 during the molding process without deformation. Therefore, the slider 24 can provide an internal support for the hollow polymer structure 10 that is stronger than or equal to the molding pressure. The fiber material 20 can be disposed adjacent to the hollow polymer structure 10 and overmolded on the hollow polymer structure 10. When the mold device is opened, the slider 24 can be removed from the hollow space 12 and the overmolded polymer article can be removed from the molding device 300.

[0035] Figure 4 It shows that Figure 1 , 2 3 or 3 are made of a hollow overmolded polymer article 30. Figure 4 As shown, the hollow polymer article 30 includes a layer of a fiber material 20 overmolded on a hollow polymer structure 10. The hollow space 12 is located inside the hollow polymer structure 10 and is defined by the hollow polymer structure 10. The overmolded fiber material 20 may include a thickness t2 of 0.5 mm to 20 mm. In addition, the hollow polymer structure 10 may include a wall thickness t1 of less than or equal to 0.5 mm. At any point on the article, the thickness t2 of the fiber material 20 overmolded on the hollow polymer structure may vary by less than or equal to 2%. Therefore, a consistent thickness can be obtained.

[0036] Figure 5 A method of making a hollow overmolded polymer article is shown. In step 100, a hollow polymer structure 10 is disposed in a molding apparatus (e.g., in a mold). In step 105, the hollow space 12 of the hollow polymer structure 10 is pressurized. In step 115, a fibrous polymer material is disposed adjacent to the hollow polymer structure 10. In step 120, the mold is opened. In step 125, a hollow polymer article 30 including a fibrous polymer material 20 overmolded on the hollow polymer structure 110 (e.g., on the outer surface of the hollow polymer structure 110) is removed from the mold.

[0037] Figure 6 A method for producing an overmolded polymer article is shown. In step 200, a prefabricated hollow polymer component 10 is placed in a molding device. In step 205, the end portions of the hollow space 12 are plugged and in step 210, internal pressure is applied to the hollow polymer component 10. In step 215, a fibrous polymer material is overmolded onto the hollow polymer component 10.

[0038] Set forth below are some embodiments of connectors and methods of making the connectors disclosed herein.

[0039] Embodiment 1: A method for manufacturing a hollow overmolded polymer article, comprising: placing a hollow polymer structure in a mold; supporting the inner surface of the hollow polymer structure; disposing a fibrous polymer material in the mold adjacent to the outer surface of the hollow polymer structure; overmolding (e.g., closing the mold to overmold) the fibrous polymer material onto the outer surface of the hollow polymer structure (e.g., in the mold); opening the mold; and removing the hollow overmolded polymer article including the fibrous polymer material overmolded on the hollow polymer structure.

[0040] Embodiment 2: The method of Embodiment 1, wherein introducing the fibrous polymer material comprises injecting the fibrous polymer material into the mold.

[0041] Embodiment 3: The method of Embodiment 1 or 2, wherein the hollow polymeric structure comprises a wall thickness less than or equal to 0.5 mm.

[0042] Embodiment 4: The method of any one of embodiments 1-3, wherein the fiber polymer material includes polybutylene terephthalate; acrylonitrile-butadiene-styrene; polycarbonate; polycarbonate / polybutylene terephthalate blends; polycarbonate / acrylonitrile-butadiene-styrene blends; copolycarbonate-polyester; acrylic-styrene-acrylonitrile; acrylonitrile-(ethylene-polypropylene diamine modified)-styrene; phenylene ether resin; polyphenylene ether / polyamide blends; polycarbonate / polyethylene terephthalate / polybutylene terephthalate blends; polybutylene terephthalate and impact modifier; polyamide; phenylene sulfide resin; polyvinyl chloride; high impact polystyrene; low / high density polyethylene; polypropylene; foamed polypropylene; and thermoplastic olefins and combinations comprising at least one of the above.

[0043] Embodiment 5: The method of any one of embodiments 1-4, wherein the fiber polymer material includes fibers comprising aramid, carbon, basalt, glass, plastic, metal, quartz, boron, cellulose, liquid crystal polymers, thermoplastic polymers, thermosetting polymers, natural fibers, and combinations comprising at least one of the above; preferably high tenacity polymers; and more preferably polypropylene, polyethylene, poly(hexamethylene-6-lactam), poly[imino(1,6-dioxyhexamethylene)iminohexamethylene], and combinations comprising at least one of the above; preferably poly[imino(1,6-dioxyhexamethylene)iminohexamethylene].

[0044] Embodiment 6: The method of any of Embodiments 1-5, wherein the fibrous polymer material comprises long glass fiber filled polypropylene.

[0045] Embodiment 7: The method of any one of embodiments 1-6, wherein supporting the inner surface of the hollow polymer structure comprises plugging the ends of the hollow polymer structure and applying a pressurized fluid to the hollow space within the hollow polymer structure, preferably wherein the fluid is a gas, and more preferably wherein the fluid is water.

[0046] Embodiment 8: The method of any of Embodiments 1-6, wherein supporting the inner surface of the hollow polymeric structure comprises plugging ends of the hollow polymeric structure and applying a pressurized gas to the hollow space within the hollow polymeric structure.

[0047] Embodiment 9: The method of any of embodiments 1-6, wherein supporting the inner surface of the hollow polymer structure includes inserting a slider into each end of the hollow polymer structure, optionally wherein the slider contacts the inner surface of the hollow polymer structure; and optionally wherein the slider has sufficient structural integrity (e.g., strength) to withstand molding pressure without deformation.

[0048] Embodiment 10: The method of any of Embodiments 1-6, wherein supporting the inner surface of the hollow polymer structure includes inserting a metal insert into the hollow polymer structure, optionally wherein the metal insert contacts the inner surface of the hollow polymer structure, and optionally wherein the metal insert has sufficient structural integrity (e.g., strength) to withstand molding pressure without deformation.

[0049] Embodiment 11: The method of any of Embodiments 1-10, wherein a cross-section of the hollow polymeric structure comprises a closed cross-sectional geometry.

[0050] Embodiment 12: The method of any of Embodiments 1-11, wherein the wall thickness of the fibrous polymer forms a wall that varies less than 2% in thickness at any point in the overmolded article.

[0051] Embodiment 13: The method of any of Embodiments 1-12, wherein the wall thickness of the fiber reinforced polymer material is at least 150% of the wall thickness of the hollow polymer structure.

[0052] Embodiment 14: The method of any one of embodiments 1-13, wherein the hollow polymer structure comprises polybutylene terephthalate; acrylonitrile-butadiene-styrene; polycarbonate; polycarbonate / polybutylene terephthalate blends; polycarbonate / acrylonitrile-butadiene-styrene blends; copolycarbonate-polyester; acrylic-styrene-acrylonitrile; acrylonitrile-(ethylene-polypropylene diamine modified)-styrene; phenylene ether resin; polyphenylene ether / polyamide blends; polycarbonate / polyethylene terephthalate / polybutylene terephthalate blends; polybutylene terephthalate and impact modifier; polyamide; phenylene sulfide resin; polyvinyl chloride; high impact polystyrene; low / high density polyethylene; polypropylene; expanded polypropylene; and thermoplastic olefins and combinations comprising at least one of the above.

[0053] Embodiment 15: A method for producing an overmolded polymer article, comprising: placing a preformed hollow polymer component in a mold; wherein the hollow polymer component is open at two end portions; plugging the two end portions, wherein one plug is connected to a pressurizing device; applying internal pressure to the hollow polymer component; and overmolding the hollow polymer component with a fibrous polymer material.

[0054] Embodiment 16: The method of embodiment 15, wherein the pressurizing device comprises a gas pressurizing device.

[0055] Embodiment 17: The method of embodiment 15, wherein the pressurizing device comprises a liquid pressurizing device.

[0056] Embodiment 18: The method of Embodiment 17, wherein the liquid comprises water, preferably cooled water.

[0057] Embodiment 19: A method according to any one of embodiments 15-18, wherein the fiber polymer material comprises polybutylene terephthalate; acrylonitrile-butadiene-styrene; polycarbonate; polycarbonate / polybutylene terephthalate blends; polycarbonate / acrylonitrile-butadiene-styrene blends; copolycarbonate-polyester; acrylic-styrene-acrylonitrile; acrylonitrile-(ethylene-polypropylene diamine modified)-styrene; phenylene ether resin; polyphenylene ether / polyamide blends; polycarbonate / polyethylene terephthalate / polybutylene terephthalate blends; polybutylene terephthalate and impact modifier; polyamide; phenylene sulfide resin; polyvinyl chloride; high impact polystyrene; low / high density polyethylene; polypropylene; expanded polypropylene; and thermoplastic olefins, as well as combinations comprising at least one of the above.

[0058] Embodiment 20: The method of any one of embodiments 15-19, wherein the fiber polymer material includes fibers comprising aramid, carbon, basalt, glass, plastic, metal, quartz, boron, cellulose, liquid crystal polymers, thermoplastic polymers, thermosetting polymers, natural fibers, and combinations comprising at least one of the above; preferably high tenacity polymers; and more preferably polypropylene, polyethylene, poly(hexamethylene-6-lactam), poly[imino(1,6-dioxyhexamethylene)iminohexamethylene], and combinations comprising at least one of the above; and more preferably poly[imino(1,6-dioxyhexamethylene)iminohexamethylene].

[0059] Embodiment 21: The method of any of Embodiments 15-20, wherein the prefabricated hollow polymer component comprises a wall thickness less than or equal to 0.5 mm.

[0060] Embodiment 22: The method of any of Embodiments 15-21, wherein a cross-section of the hollow polymeric component comprises a closed cross-sectional geometry.

[0061] Embodiment 23: The method of any of Embodiments 15-22, wherein the fibrous polymer forms a wall thickness that varies less than 2% in thickness at any point in the overmolded article.

[0062] Embodiment 24: The method of any of Embodiments 1-23, wherein the hollow polymer structure comprises polycarbonate.

[0063] Embodiment 25: The method of any one of embodiments 1-24, wherein the density of the material of the fiber polymer and the hollow polymer structure is less than or equal to 1.5 g / cm 3 .

[0064] Embodiment 26: A vehicle component produced by the method of any one of Embodiments 1-25.

[0065] Embodiment 27: A vehicle, comprising: a structural body; and the vehicle component of embodiment 26.

[0066] Embodiment 28: A hollow overmolded polymer article comprising: a fibrous polymer overmolded onto a hollow polymer structure; wherein the hollow polymer structure comprises a wall thickness less than or equal to 0.5 mm.

[0067] Embodiment 29: The article of embodiment 28, wherein the fiber polymer material includes polybutylene terephthalate; acrylonitrile-butadiene-styrene; polycarbonate; polycarbonate / polybutylene terephthalate blends; polycarbonate / acrylonitrile-butadiene-styrene blends; copolycarbonate-polyester; acrylic-styrene-acrylonitrile; acrylonitrile-(ethylene-polypropylene diamine modified)-styrene; phenylene ether resin; polyphenylene ether / polyamide blends; polycarbonate / polyethylene terephthalate / polybutylene terephthalate blends; polybutylene terephthalate and impact modifier; polyamide; phenylene sulfide resin; polyvinyl chloride; high impact polystyrene; low / high density polyethylene; polypropylene; foamed polypropylene; and thermoplastic olefins, as well as combinations comprising at least one of the above.

[0068] Embodiment 30: The article of any one of embodiments 28-29, wherein the fiber polymer material includes fibers comprising aramid, carbon, basalt, glass, plastic, metal, quartz, boron, cellulose, liquid crystal polymers, thermoplastic polymers, thermosetting polymers, natural fibers, and combinations comprising at least one of the above; preferably high tenacity polymers; and more preferably polypropylene, polyethylene, poly(hexamethylene-6-lactam), poly[imino(1,6-dioxyhexamethylene)iminohexamethylene], and combinations comprising at least one of the above, and more preferably poly[imino(1,6-dioxyhexamethylene)iminohexamethylene].

[0069] Embodiment 31: The article of any of Embodiments 28-30, wherein the fibrous polymer material comprises long glass fiber-filled polypropylene.

[0070] Embodiment 32: The article of any of Embodiments 28-31, wherein a cross-section of the hollow polymeric structure comprises a closed cross-sectional geometry.

[0071] Embodiment 33: The article of embodiment 32, wherein the cross-section of the hollow polymer structure comprises a circle, an ellipse, a polygon, and combinations thereof.

[0072] Embodiment 34: The article of any of Embodiments 28-33, wherein the cross-section of the periphery of the overmolded polymeric structure is different than the cross-section of the periphery of the hollow polymeric structure.

[0073] Embodiment 35: The article of any one of embodiments 28-34, wherein the density of the material of the fiber polymer and the hollow polymer structure is less than or equal to 1.5 g / cm 3 .

[0074] Embodiment 36: An article of any one of embodiments 28-35, wherein the hollow polymer structure comprises polybutylene terephthalate; acrylonitrile-butadiene-styrene; polycarbonate; polycarbonate / polybutylene terephthalate blends; polycarbonate / acrylonitrile-butadiene-styrene blends; copolycarbonate-polyester; acrylic-styrene-acrylonitrile; acrylonitrile-(ethylene-polypropylene diamine modified)-styrene; phenylene ether resin; polyphenylene ether / polyamide blends; polycarbonate / polyethylene terephthalate / polybutylene terephthalate blends; polybutylene terephthalate and impact modifier; polyamide; phenylene sulfide resin; polyvinyl chloride; high impact polystyrene; low / high density polyethylene; polypropylene; expanded polypropylene; and thermoplastic olefins, as well as combinations comprising at least one of the above.

[0075] Embodiment 37: A vehicle component comprising the article of any of Embodiments 28-36.

[0076] Embodiment 38: A vehicle comprising: a structural body; and the vehicle component of embodiment 37.

[0077] The present invention may alternatively include, consist of, or consist essentially of any suitable components disclosed herein. The present invention may be additionally or alternatively formulated to be free of or substantially free of any components, materials, ingredients, adjuvants or substances used in prior art compositions or otherwise not necessary to achieve the functions and / or purposes of the present invention.

[0078] All ranges disclosed herein include endpoints, and the endpoints are independently combinable with each other (e.g., a range of "up to 25 wt.%, or more specifically 5 wt.% to 20 wt.%" includes the endpoints of the range of "5 wt.% to 25 wt.%" and all intermediate values, etc.). "Combination" includes blends, mixtures, alloys, reaction products, etc. In addition, the terms "first", "second", etc., herein do not indicate any order, quantity, or importance, but are used to indicate one element with another. The terms "one" and "a" and "the" herein do not indicate a limitation on quantity, but are interpreted as including both the singular and the plural, unless otherwise indicated herein or clearly contradicted by the context. As used herein, the suffix "(s)" is intended to include both the singular and the plural of the term it modifies, thereby including one or more of the terms (e.g., film (film(s)) includes one or more films). "One embodiment", "another embodiment", "embodiment", etc. mentioned throughout the specification means that the specific elements (e.g., features, structures and / or characteristics) described in conjunction with the embodiment are included in at least one embodiment described herein, and may or may not be present in other embodiments. In addition, it is to be understood that in the various embodiments, the described elements may be combined in any suitable manner.

[0079] Although specific embodiments have been described, unforeseen or perhaps presently unforeseen alternatives, modifications, variations, improvements, and substantial equivalents may occur to the applicant or others skilled in the art. Accordingly, the appended claims as filed and as they may be amended are intended to include all such alternatives, modifications, variations, improvements, and substantial equivalents.

Claims

1. A method for producing a hollow overmolded polymer article (30), wherein: The hollow overmolded polymer article (30) is a structural reinforcement component for use in a vehicle component selected from a door module, a front end module, a dashboard tray, and a bumper cladding of a vehicle structure, the method comprising: placing a hollow polymer structure (10) in a mold of a molding device (100, 200, 300), wherein the hollow polymer structure (10) has an inner surface and an outer surface, and wherein the hollow polymer structure (10) is open at both ends; supporting the inner surface; placing a fibrous polymer material (20) in a mold adjacent to the outer surface; overmolding the fibrous polymer material (20) onto the outer surface; opening the mold; and removing the hollow overmolded polymer article (30) comprising the fibrous polymer material (20) overmolded onto the hollow polymer structure (10); Wherein, the inner surface supporting the hollow polymer structure (10) comprises: plugging the ends of the hollow polymer structure (10) and applying a pressurized fluid to the hollow space (12) within the hollow polymer structure (10) using a fluid pressurizing device; or plugging the ends of the hollow polymer structure (10) and applying pressurized gas to the hollow space (12) within the hollow polymer structure (10); or inserting a slider (24) into the hollow polymer structure (10), wherein the slider (24) contacts the inner surface of the hollow polymer structure (10); or inserting a metal insert (26) into the hollow polymer structure (10), wherein the metal insert contacts an inner surface of the hollow polymer structure (10); wherein the fibrous polymer material overmolded onto the hollow polymer structure (10) has a thickness greater than or equal to 150% of the thickness of the hollow polymer structure (10), wherein the hollow polymer structure (10) has a wall thickness t1 less than or equal to 0.5 mm, wherein the thickness of the fibrous polymer material overmolded onto the hollow polymer structure (10) varies by less than or equal to 2% at any point on the article, thereby achieving a consistent thickness.

2. The method of claim 1, wherein the vehicle component is a lift gate.

3. The method according to claim 1 or 2, wherein: The introduction of the fibrous polymer material (20) is achieved by injecting the fibrous polymer material (20) into the mould.

4. The method according to claim 1 or 2, wherein: At least one of the fibrous polymer material (20) and the hollow polymer structure (10) comprises at least one of the following: polybutylene terephthalate; acrylonitrile-butadiene-styrene; polycarbonate; acrylic-styrene-acrylonitrile; acrylonitrile-(ethylene-polypropylene diamine modified)-styrene; phenylene ether resin; polyamide; phenylene sulfide resin; thermoplastic olefin.

5. The method according to claim 1 or 2, wherein: At least one of the fibrous polymer material (20) and the hollow polymer structure (10) comprises at least one of: a polycarbonate / polybutylene terephthalate blend; a polycarbonate / acrylonitrile-butadiene-styrene blend; a polyphenylene ether / polyamide blend; a polycarbonate / polyethylene terephthalate / polybutylene terephthalate blend; polybutylene terephthalate and an impact modifier.

6. The method according to claim 1 or 2, wherein: At least one of the fibrous polymer material (20) and the hollow polymer structure (10) comprises at least one of: copolycarbonate-polyester; polyvinyl chloride; low / high density polyethylene; polypropylene; high impact polystyrene.

7. The method according to claim 1 or 2, wherein: At least one of the fibrous polymer material (20) and the hollow polymer structure (10) comprises foamed polypropylene.

8. A vehicle component comprising a hollow overmolded polymeric article manufactured according to any one of claims 1 to 7 and being a structural reinforcement component, the article comprising: a fibrous polymer material (20) overmolded onto the hollow polymer structure (10); wherein the hollow polymer structure (10) comprises a wall thickness t1 less than or equal to 0.5 mm; and The density of the fiber polymer material (20) and the material of the hollow polymer structure (10) is less than or equal to 1.5 g / cm 3 ;and wherein the vehicle component is selected from a door module, a front end module, a dashboard bracket and a bumper cladding of a vehicle structure, and wherein the fibrous polymer material overmolded onto the hollow polymer structure (10) has a thickness greater than or equal to 150% of the thickness of the hollow polymer structure (10), and wherein the thickness of the fibrous polymer material overmolded onto the hollow polymer structure (10) varies by less than or equal to 2% at any point on the article, thereby achieving a consistent thickness.

9. The vehicle component of claim 8, wherein the vehicle component is a lift gate.

10. A vehicle comprising: Structural body; as well as The vehicle component according to claim 8 or 9.

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