Inflatable-based method for manufacturing a multi-layer internal reinforcement

Abstract

A structural component of a vehicle and a method and system for forming the structural component. A first cavity is formed within a first hollow channel between a first airbag and an interior surface of a component forming the structural component. A first structural reinforcement layer is formed within the first cavity by filling the first cavity with a first polymeric resin and foaming the first polymeric resin to form a first polymeric resin foam. A second cavity is formed within the first hollow channel and a second structural reinforcement layer is formed within the second cavity by filling the second cavity with a second polymeric resin and foaming the second polymeric resin to form a second polymeric resin foam.

Description

Technical Field

[0001] Structural foam serves as a lightweight solution for reinforcing and strengthening vehicle structures. In various applications, structural foam is used internally in hollow structural components. It can be used to manage collision energy forces and address noise, vibration, and acoustic harshness (NVH). Furthermore, the use of foam helps reduce vehicle weight, thereby improving fuel efficiency. Background Technology

[0002] Structural foam is foamed in place and can be formed using low-pressure injection molding. In low-pressure injection molding, foam is introduced into the hollow channels of the structural component and allowed to rise freely in place. Gravity can be used to confine the rise. However, when using this method, the foam fills the entire cross-section of the hollow channel. Furthermore, if the finite cross-section of the structural component includes structural foam or if structural foam of different materials is used in different locations, it may be necessary to form each part in a separate step, or to form multiple parts comprising at least different materials. This typically requires multiple molding stations and molding cycles to fill a single component.

[0003] Therefore, while current structural foam reinforcement methods have achieved their intended purpose, a new and improved system and method for forming structural foam reinforcements is needed. Summary of the Invention

[0004] According to various aspects, this disclosure relates to a method of forming a structural component of a vehicle. The method includes forming a first cavity within a first hollow channel between a first airbag and the inner surface of the component. Additionally, the method includes forming a first structural reinforcement layer within the first cavity by filling the first cavity with a first polymeric resin and foaming the first polymeric resin to form a first polymeric resin foam. The method further includes forming a second cavity within the first hollow channel. Additionally, the method includes forming a second structural reinforcement layer within the second cavity by filling the second cavity with a second polymeric resin and foaming the second polymeric resin to form a second polymeric resin foam.

[0005] In the aforementioned respect, the first polymer resin foam and the second polymer resin foam partially fill the first hollow channel.

[0006] In any of the above aspects, the method further includes inflating the first airbag with a first fluid.

[0007] In any of the above aspects, the method further includes removing the first airbag from the first hollow channel after the first polymer resin foam has been formed.

[0008] In an additional aspect, the method further includes inserting a second airbag into the first hollow channel and inflating it after removing the first airbag from the first hollow channel, wherein the second cavity is formed between the second airbag and the first structural reinforcement layer.

[0009] In the aforementioned respect, the second cavity is formed between the second airbag, the first structural reinforcement layer, and the inner surface of the component.

[0010] In a further aspect described above, the method also includes removing the second airbag.

[0011] In addition, the second airbag is connected to the outer surface of the first airbag, and a second cavity appears when the first airbag is inflated.

[0012] In a further aspect described above, the method also includes adhering the outer surface of the second airbag to the first structural reinforcement layer.

[0013] In a further aspect described above, the method also includes removing the first airbag after filling the second cavity with the second polymer resin.

[0014] In an additional aspect described above, the method includes forming a second cavity between a first airbag and a second airbag located within the first airbag.

[0015] In a further aspect described above, the method also includes disconnecting the first supply line and the second supply line from the first airbag and the second airbag.

[0016] According to various additional aspects, this disclosure relates to a system for forming a structural component of a vehicle. The system includes a component comprising a first hollow channel defined by an inner surface of the component. The system also includes a first inflatable airbag insertable into the first hollow channel of the component, wherein the first inflatable airbag and the inner surface of the component define a first cavity within the first hollow channel. The system further includes a second inflatable airbag insertable into the first hollow channel, wherein the second inflatable airbag defines a second cavity within the first hollow channel.

[0017] In the aforementioned respects, the system further includes: a first gating system connected to the first cavity via a first port defined in the component.

[0018] In any of the above aspects, the system further includes: a second gating system connected to the second cavity via a second port defined in the component.

[0019] In any of the above aspects, the second inflatable airbag is fixed to the first inflatable airbag.

[0020] In the above respects, the second inflatable airbag is connected to the outer surface of the first inflatable airbag.

[0021] In a further aspect described above, the second inflatable airbag includes an adhesion promoter layer.

[0022] According to various additional aspects, this disclosure relates to a structural component of a vehicle. The structural component includes a component having an inner surface defining a first hollow channel. The structural component also includes a first structural reinforcement contacting the inner surface of the component, the first structural reinforcement being formed of a first polymeric resin foam. The structural component further includes a second structural reinforcement contacting the first structural reinforcement, the second structural reinforcement being formed of a second polymeric resin foam. The first and second structural reinforcements form a multilayer structural reinforcement, and the component defines a cross-section and the multilayer structural reinforcement partially fills that cross-section.

[0023] In the above respects, the adhesion promoter layer is located between the first structural reinforcement and the second structural reinforcement. Attached Figure Description

[0024] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of this disclosure in any way.

[0025] Figure 1A A vehicle frame, comprising several structural components in a vehicle, is shown according to various aspects of this disclosure.

[0026] Figure 1B A structural component including a structural reinforcement formed therein is shown according to an embodiment of the present disclosure.

[0027] Figure 1C An embodiment according to this disclosure is shown. Figure 1B The cross-section of the structural component.

[0028] Figure 2 A general method for forming a multilayered foam reinforcement in a structural component according to an embodiment of the present disclosure is shown.

[0029] Figure 3 A method for forming a multilayer structured foam reinforcement in a component is shown according to an embodiment of the present disclosure.

[0030] Figure 4A An uninflated airbag inserted into a structural component according to one embodiment of the present disclosure is shown.

[0031] Figure 4B An airbag inflated within a structural component is shown according to one embodiment of the present disclosure, with a cavity formed between the airbag and the structural component.

[0032] Figure 4C The illustration shows the introduction of a polymer resin foam according to one embodiment of the present disclosure, introduced into a cavity formed between a structural component and an inflatable airbag.

[0033] Figure 4D A structural reinforcement formed in a structural component and a deflation airbag according to an embodiment of the present disclosure is shown.

[0034] Figure 4E A structural component according to one embodiment of the present disclosure is shown, the structural component including a plurality of structural reinforcements formed in the structural component after the deflation airbag is removed.

[0035] Figure 4F The insertion of a second uninflated airbag according to one embodiment of the present disclosure is shown, inserted into a structural component and a first reinforcing layer.

[0036] Figure 4G A second airbag after inflation is shown according to one embodiment of the present disclosure.

[0037] Figure 4H The formation of a second layer of structural reinforcement in a structural component is shown according to an embodiment of the present disclosure.

[0038] Figure 4I The multi-layered structural components after the removal of the second airbag are shown according to one aspect of this disclosure.

[0039] Figure 5 A method for forming a multilayered foam reinforcement in a component is shown according to one embodiment of the present disclosure.

[0040] Figure 6A A structural component including an uninflated airbag is shown according to an embodiment of the present disclosure, the uninflated airbag including a second airbag disposed outside the uninflated airbag.

[0041] Figure 6B A first airbag inflated within a structural component is shown according to one embodiment of the present disclosure.

[0042] Figure 6C The illustration shows the introduction of a first polymer resin foam according to one embodiment of the present disclosure, introduced into a cavity defined by a structural component and a first inflatable airbag.

[0043] Figure 6D The introduction of a second polymer resin foam into a second airbag is shown according to one embodiment of the present disclosure.

[0044] Figure 6E The deflation of a first airbag according to an embodiment of the present disclosure is shown.

[0045] Figure 6F An embodiment according to this disclosure is shown. Figures 6A to 6E A variation of the second airbag, wherein the second airbag includes an adhesive accelerator layer.

[0046] Figure 7 A method for forming a multilayered foam reinforcement in a component is shown according to one embodiment of the present disclosure.

[0047] Figure 8A The insertion of a first uninflated airbag, including a second uninflated airbag, into a structural component is shown according to one embodiment of the present disclosure.

[0048] Figure 8B The inflation of a first uninflated airbag, including a second uninflated airbag, into a structural component is shown according to one embodiment of the present disclosure.

[0049] Figure 8C The introduction of a first polymer resin foam into a structural component is shown according to one embodiment of the present disclosure.

[0050] Figure 8D The inflation of a second airbag within a first airbag according to an embodiment of the present disclosure is shown.

[0051] Figure 8E The introduction of a second polymer resin foam according to one embodiment of the present disclosure is shown, introduced between the first airbag and the second airbag.

[0052] Figure 8F The removal of the guide wire from the first airbag is shown according to one embodiment of the present disclosure.

[0053] Figure 9A An embodiment of the present disclosure is shown for use with Figures 8A to 8F The stacking of airbags in the middle.

[0054] Figure 9B A sealed image according to an embodiment of the present disclosure is shown. Figure 9A The stacking of airbags.

[0055] Figure 9C An embodiment of the present disclosure is shown, which is rolled up and tightened at the end and includes a supply line. Figure 9A The stacking of airbags. Detailed Implementation

[0056] The following description is merely exemplary in nature and is not intended to limit this disclosure, its application, or its uses. Furthermore, it is not intended to be bound by any express or implied theory set forth in the foregoing introduction, summary of the invention, or the following detailed description. It should be understood that throughout the drawings, corresponding reference numerals indicate similar or corresponding parts and features.

[0057] As used herein, the term "vehicle" is not limited to automobiles. While this technology is described primarily in connection with automobiles, it is not limited to automobiles. These concepts can be used in a wide variety of applications, such as those related to motorcycles, mopeds, locomotives, aircraft, ships, and other vehicles, or other structural or non-structural applications that may require the deposition of polymer resins in component channels.

[0058] This disclosure relates to structural components including multilayer structural reinforcements, an inflatable-based system for forming multilayer structural reinforcements within the structural component, and an inflatable-based method for controlling the molding of multilayer structural foam reinforcements. The structural component includes parts that perform at least one of the following functions: supporting vehicle weight, absorbing road impacts, and managing collision energy. Structural reinforcements are understood herein as materials that improve the mechanical properties of the structural component, such as the compressive strength, flexural strength, tensile strength, or energy absorption capacity of the structural component.

[0059] Figure 1A A vehicle 100 is shown, including a frame 102, which includes several structural components 103, such as A-pillar 104 and B-pillar 106. Figure 1B and Figure 1C B-pillar 106 is shown. Structural member 103 is formed by member 112 including a hollow channel. For example, B-pillar 106 is formed by member 112, which includes an inner surface 114 defining a first hollow channel 116 within member 112. The first hollow channel 116 is an elongated hollow channel. Structural reinforcements 120, 122, 124, and 126 contact the inner surface 114 of member 112 and are discretely formed at different locations within the first hollow channel 116 of member 112.

[0060] In addition, one or more of the structural reinforcements 120, 122, 124, and 126 are formed of multiple layers, and each of the structural reinforcements and layers is formed of a polymer resin foam having a honeycomb structure. Figure 1C A multilayer structural reinforcement 122 is shown, comprising a first structural reinforcement layer 132 composed of a first polymer resin foam comprising a first polymer resin and a second structural reinforcement layer 134 composed of a second polymer resin foam comprising a second polymer resin. Although the structural reinforcement layers are shown as concentric, it should be understood that other geometries may be shown. Four structural reinforcements are provided as shown; however, it should be understood that one or more structural reinforcements may be provided for a single structural component 103, for example, between one and ten structural reinforcements. Furthermore, where multiple structural reinforcements may be present, the structural reinforcements may be made of a variety of materials with different compositions, physical properties, and mechanical properties.

[0061] The multilayer reinforcement members 120, 122, 124, and 126 only partially fill a given cross-section of the first hollow channel 116 of member 112, without filling the entire cross-section of the first hollow channel 116. For example... Figure 1C As shown, the multi-layer structural reinforcement 122 fills a portion of the cross-section of the first hollow channel 116 and is hollow, defining the second hollow channel 130. In other aspects, the multi-layer structural reinforcement 122 fills a portion of the cross-section of the first hollow channel 116, and the second hollow channel 130 is defined by both the multi-layer structural reinforcement 122 and component 112. In some aspects, the multi-layer structural reinforcement 122 blocks a given cross-section of the first hollow channel 116 in the range of 5% to 90% (inclusive). Partially filling component 112 with a multi-layer structural reinforcement reduces the weight of structural component 103 compared to completely filling structural component 103 with a structural reinforcement, thus contributing to a reduction in the overall weight of the vehicle 100.

[0062] Figure 2 A general method 200 for forming multi-layer structural reinforcements 120, 122, 124, 126 within a structural member 103 (e.g., B-pillar 106) is shown. At block 202, a first airbag is inserted into the structural member. In some aspects, a second airbag is integrated with the first airbag, either surrounding the exterior of the first airbag or located within the first airbag. At block 204, a first cavity is formed by inflating the first airbag. At block 206, the first cavity is filled with a first polymeric resin foam, forming the first structural reinforcement. If it has not yet been formed by inflating the first airbag, at block 208, a second cavity is formed by inflating the second airbag. Therefore, it should be understood that block 208 is optional depending on the construction of the first and second airbags. At block 210, the second cavity is filled with polymeric resin foam, forming the second structural reinforcement.

[0063] In the above respects, refer to Figure 3 and Figures 4A to 4IThis paper describes a method and system for forming a structural component 103 of a vehicle. Method 300 begins at block 302 by inserting an uninflated, insertable first airbag 402 into a first hollow channel 404 defined by an inner surface 406 of a component 408 forming the structural component 400. The first airbag 402 includes guide lines 410, 412 connected to and extending from either side of the first airbag 402 to aid in positioning the first airbag 402 within the component 408. The guide lines 410, 412 also include attachment rings 414, 416 for positioning the first airbag 402 within the component 408 and securing the first airbag 402 in place to prevent movement of the first airbag 402 within the component 408 during forming. The attachment rings 414, 416 may be connected to the structural component 400 or to a fixing device that holds the structural component 400 in place during forming. In some respects, the first airbag 402 is formed of silicone resin, polypropylene, polyamide-reinforced polypropylene, or rubber.

[0064] The first airbag 402 also includes confined portions 420, 422, and 424, which exhibit less expansion than the rest of the first airbag 402 when inflated. The confined portions 420, 422, and 424 can be formed by winding wire, metal wire, tape, or elastic band around the first airbag 402, or by forming the confined portions 420, 422, and 424 of the first airbag 402 with one or more different materials, which exhibit different degrees of ductility or deformation when force is applied to the first airbag 402 by the fluid 428 that inflates the airbag 402. Different geometries of the first airbag 402 and structural reinforcements 120, 122, 124, and 126 can be formed by changing the number or position of the windings or by using different materials. Therefore, although three confined portions are shown, any number of confined portions can be provided, for example, from one to ten confined portions. Furthermore, it should be understood that although the restricted portion is shown extending around the entire periphery of the first airbag 402, the restricted portion may be limited to several segments of the airbag periphery. In addition to the restricted portion, an inflatable portion exhibiting greater extensibility than the rest of the airbag 402 may also be provided. The restricted portions 420, 422, and 424 limit the degree to which the first airbag 402 is inflatable relative to the rest of the airbag 402 within a given region, and when the airbag is inflated, the inflatable portion inflates to a greater extent relative to the rest of the first airbag 402.

[0065] In box 304, refer to Figure 4BThe first airbag 402 inflates by filling it with fluid 428 (e.g., air, inert gas, or liquid) via a supply line 430 connected to the interior 432 of the first airbag 402. In the illustrated aspect, the first airbag 402 impacts and contacts the inner surface 406 of the component 408 to define a plurality of first cavities 434, 436, 438 between the outer surface 406 of the component 408 and the first airbag 402. The shape and inflation pressure of the inflatable airbag are chosen such that when the airbag is pressed against the inner surface 406 of the component 408, the airbag forms a tight seal around the boundaries of the cavities 434, 436, 438. It should be understood that although a plurality of cavities are shown, one or two or more cavities may be defined between the inner surface 406 of the component 408 and the first airbag 402. In some respects, the temperature of fluid 428 can be adjusted, for example by circulating the fluid through a cooler or heater, to facilitate the molding of the structural reinforcement by aiding in the curing or cooling of the resin subsequently introduced into the first cavities 434, 436, 438. In some respects, the first airbag 402 is coated with a release agent or otherwise treated to prevent the first airbag 402 from adhering to the polymer resin foam further described herein.

[0066] After the first airbag 402 is filled in box 304, refer to box 306. Figure 4CThe first cavities 434, 436, and 438 are filled with a first polymeric resin to form a first polymeric resin foam 440, which produces first layer structural reinforcements 442, 444, and 446. In some aspects, the first polymeric resin releases gas through a chemical reaction to form the first polymeric resin foam 440. Alternatively, the first polymeric resin foam 440 includes a foaming agent or expandable particles that expand to form a foam. In some aspects, foaming can be triggered by heating the polymeric resin before or after it enters the cavity. Examples of the first polymeric resin foam 440 include, for example, a partial or partial foam, a thermoplastic material comprising expandable particles or a foaming agent, or a thermoplastic material mixed with gas after melting and before molding. The first polymer resin used to form the first polymer resin foam 440 includes, for example, one or more of the following: polyurethane, epoxy resin, polyisocyanurate, ethylene vinyl acetate, polyolefin, polyolefin-ethylene vinyl acetate blend, polybutylene terephthalate, polycarbonate, polyphenylene ether, polyethylene terephthalate, and acrylonitrile butadiene styrene. As described above, when a given structural component 400 includes multiple structural reinforcements 442, 444, 446, more than one type of first polymer resin foam 440 can be used. Different first polymer resins or different amounts of polymer resin can be used to form the first polymer resin foam 440 of each structural reinforcement, or the same first polymer resin with different amounts of blowing agent can be used. Different first polymer resin foams 440 can exhibit different densities or different mechanical properties, including compressive strength and tensile strength. In an additional or alternative aspect, different amounts of polymer resin can be injected into a given cavity to provide polymer resin foams of different densities.

[0067] The first polymer resin forming the first polymer resin foam 440 is introduced by a runner system 450. In some aspects, the runner system 450 is formed in one or more fixtures 452, on which the component 408 is held. In other aspects, the runner system 450 is formed by tubing connectable to the component 408. The component 408 defines a plurality of ports 456, 458, 460 that connect first cavities 434, 436, 438 to the runner system 450 to introduce the first polymer resin of the first polymer resin foam 440 into the first cavities 434, 436, 438 before or after foaming the first polymer resin. Furthermore, the runner system 450 is connected to a first polymer resin supply system 454. In some aspects, the first polymer resin supply system 454 includes one or more of the following: a supply tank, a reservoir, a metering pump, a feeder, an extruder, and a mixer. In some respects, each port 456, 458, 460 is connected to an independent gating system 450, which in turn is connected to its own polymer resin supply system 464. Each polymer resin supply system 454 is individually metered so that a precise amount of polymer resin is supplied to each cavity 434, 436, 438. Furthermore, vents 462, 464, 466 are defined on component 408 and connected to the first cavities 434, 436, 438 to expel air from the first cavities 434, 436, 438 when the first polymer resin of the first polymer resin foam 440 is injected into the first cavities 434, 436, 438.

[0068] Alternatively, before filling the first cavities 434, 436, 438, the first polymer resin is melted, multiple raw material components of the first polymer resin are mixed, or the first polymer resin is melted and combined with a gas. For example, when a thermoplastic resin is used, the first polymer resin is melted by heating and, in some respects, combined with a gas. In another example, when a two-component polyurethane or epoxy resin is used, the resin components are mixed. Alternatively, in an alternative manner, the first polymer resin is introduced without pretreatment (e.g., melting, mixing, or combining with a gas), for example, in the case of a one-component polyurethane.

[0069] After the first polymer resin of the first polymer resin foam 440 fills the first cavities 434, 436, and 438, the first polymer resin crosslinks or cures within the first cavities 434, 436, and 438. For example, when the first polymer resin is a two-component mixture, the first polymer resin can form crosslinks and cure to form the first polymer resin foam 440. In other examples, heating the first polymer resin to initiate crosslinking, removing the foaming agent from the molten first polymer resin, or expanding the expandable particles in the molten first polymer resin can cause gas release or expansion, forming the first polymer resin foam 440. When the first polymer resin of the first polymer resin foam 440 is provided as a melt, the foamed first polymer resin can be cooled and cured. It should be understood that the first polymer resin does not need to be fully crosslinked or fully cooled to ambient temperature, but only needs to be sufficiently crosslinked or sufficiently cooled so that the first layer structural reinforcements 442, 444, and 446 can resist deformation when the first airbag 402 is removed.

[0070] Reference Figure 4D and Figure 4E Once the first polymer resin foam 440 has fully cured, in box 308, the first airbag 402 is deflated and removed from the first layer of structural reinforcements 442, 444, 446 on the inner surface 406 of the structural member 400 and the contact member 408. In some respects, the first airbag 402 can be deflated simply by reducing the pressure of the fluid 428 applied to the first airbag 402 by pumping liquid out of the first airbag 402 or by elastic recovery of the first airbag 402 or an external source. As shown, the structural reinforcements 120, 122, 124, 126, 442, 444, 446 are shaped according to the shapes of the members 112, 408 and the airbag 402.

[0071] In box 310, refer to Figure 4FThe method of forming another second layer structural reinforcement begins by inserting an uninflated insertable second airbag 403 into a first hollow channel 404 defined by the inner surface 406 of component 408 and one or more second hollow channels 405 defined by first layer structural reinforcements 442, 444, 446. The second airbag 403 includes guide lines 411, 413 connected to and extending from either side of the second airbag 403 to aid in positioning the second airbag 403 within component 408. The guide lines 411, 413 also include attachment rings 415, 417 for securing the second airbag 403 in place to prevent movement of the second airbag 403 within component 408 during molding. The attachment rings 415, 417 may be connected to structural component 400 or to a fixing device that holds structural component 400 in place during molding. In some aspects, the second airbag 403 is formed of silicone, polypropylene, polyamide-reinforced polypropylene, or rubber. In some respects, the second airbag 403 is coated with a release agent or treated to prevent the second airbag 403 from adhering to the polymer resin foam further described herein.

[0072] Similar to the first airbag 402, the second airbag 403 also includes one or more confined portions 421, which exhibit less expansion when the second airbag 403 is inflated than the rest of the second airbag 403. The confined portions 421 can be formed by winding wire, metal wire, strip, or elastic band around the second airbag 403, or by forming the confined portions 421 of the second airbag 403 with one or more different materials that exhibit different degrees of ductility or deformation when force is applied to the second airbag 403 by the fluid 429 that inflates the airbag 403. Different geometries of the second airbag 403 and structural reinforcements 120, 443 can be formed by changing the number or position of the windings or by using different materials. Therefore, although one confined portion of the second airbag 403 is shown, any number of confined portions can be provided, for example, from one to ten confined portions. Furthermore, it should be understood that although the confined portion is shown as extending around the entire periphery of the second airbag 403, the confined portion may be limited to a few segments around the periphery of the airbag. In addition to the restricted portion, an inflatable portion may also be provided. The restricted portion 421 limits the extent to which the second airbag 403 can inflate relative to other portions of the second airbag 403 within a given region, and when the airbag inflates, the inflatable portion inflates to a greater extent relative to other portions of the second airbag 403.

[0073] In box 312, refer to Figure 4GThe second airbag 403 inflates by filling it with fluid 429 (e.g., air, inert gas, or liquid) via a second supply line 431 connected to the interior 433 of the second airbag 403. In the illustrated aspect, the second airbag 403 impacts and contacts the inner surface 406 of the component 408 to define a second cavity 435 between the inner surface 406 of the component 408, the first layer structural reinforcements 442, 444, 446, and the second airbag 403. It should be understood that although a single second cavity 435 is shown, multiple cavities may be defined. In some aspects, the temperature of the fluid 429 may be adjusted, for example by circulating the fluid 429 through a cooler or heater, to facilitate the molding of the structural reinforcement by aiding in the curing or cooling of resin later introduced into the second cavity 435.

[0074] After the second airbag 403 is filled in box 312, refer to box 314. Figure 4H The second cavity 435 is filled with the second polymer resin that forms the second polymer resin foam 441, which produces the second layer structural reinforcement 443. Similar to the first layer structural reinforcements 442, 444, and 446, in some aspects, the second polymer resin releases gas through a chemical reaction to form the second polymer resin foam 441. Alternatively, the second polymer resin foam 441 includes a foaming agent or expandable particles that expand to form the foam. In some aspects, foaming can be triggered by heating the second polymer resin. Examples of the second polymer resin foam 441 include, for example, a partial or partial foam, a thermoplastic material comprising expandable particles or a foaming agent, or a thermoplastic material mixed with gas after melting and before molding. The second polymer resin used to form the second polymer resin foam 441 includes, for example, one or more of the following: polyurethane, epoxy resin, polyisocyanurate, ethylene vinyl acetate, polyolefin, polyolefin-ethylene vinyl acetate blend, polybutylene terephthalate, polycarbonate, polyphenylene ether, polyethylene terephthalate, and acrylonitrile butadiene styrene. As described above, when a given structural component 400 includes multiple structural reinforcements, more than one type of second polymer resin foam 441 can be used. Different second polymer resins can be used to form the second polymer resin foam 441 of each structural reinforcement, or the same second polymer resin with different amounts of blowing agent can be used. Different second polymer resin foams 441 can exhibit different densities or different mechanical properties, including compressive strength and tensile strength. As an addition or alternative, different amounts of polymer resin can be injected into a given cavity to provide polymer resin foams of different densities.

[0075] The second polymer resin forming the second polymer resin foam 441 is introduced through a second runner 451. In some aspects, the second runner system 451 is formed in one or more fixtures 452, on which the component 408 is held. Alternatively or additionally, the second runner system 451 is formed by a tube connectable to the component 408. As shown, the component 408 defines one port 457, or multiple ports, which connect to the second cavity 435 and are connectable to the runner system 451 to introduce the second polymer resin of the second polymer resin foam 441 into the second cavity 435 before or after foaming the second polymer resin. Furthermore, the runner system 451 is connected to a second polymer resin supply system 455. In some aspects, the second polymer resin supply system 455 includes one or more of the following: a supply tank, a reservoir, a metering pump, a feeder, an extruder, and a mixer. As described above, if more than one second cavity 435 and more than one port 457 are provided, each port can be connected to a dedicated polymer resin supply system 455 using a dedicated runner system 451. Furthermore, an exhaust port 463 is defined on component 408 and connected to the second cavity 435 to expel air from the second cavity 435 when the second polymer resin of the second polymer resin foam 441 is injected into the second cavity 435. It should be understood that during the formation of the first layer structural reinforcements 442, 444, 446, the first airbag 402 separates the port 457 used for forming the second layer structural reinforcement 443 and the exhaust port 463. Additionally, during the formation of the second layer structural reinforcement 443, the second airbag 403 separates the ports 456, 458, 460 used for forming the first layer structural reinforcements 442, 444, 446 and the exhaust ports 462, 464, 466.

[0076] Alternatively, prior to filling the second cavity 435, the second polymer resin is melted, various raw material components of the second polymer resin are mixed, or the second polymer resin is melted and combined with a gas. For example, when a thermoplastic resin is used, the second polymer resin is melted by heating and, in some respects, combined with a gas. In another example, when a two-component polymer resin such as polyurethane or epoxy resin is used, the resin components are mixed. Alternatively, in an alternative manner, the second polymer resin is introduced without pretreatment (e.g., melting, mixing, or combining with a gas), for example, in the case of a one-component polyurethane.

[0077] After the second polymer resin of the second polymer resin foam 441 fills the second cavity 435, the second polymer resin crosslinks or cures within the second cavity 435. For example, when the second polymer resin is a two-component mixture, the second polymer resin can form crosslinks and cure into the second polymer resin foam 441. In other examples, heating the second polymer resin to initiate crosslinking or remove the foaming agent while it is in a molten state, or expanding expandable particles while the second polymer resin is in a molten state, can cause gas release or expansion, forming the second polymer resin foam 441. When the second polymer resin of the second polymer resin foam 441 is provided as a melt, the foamed second polymer resin can be cooled and cured. It should be understood that the second polymer resin does not need to be fully crosslinked or fully cooled to ambient temperature, but only needs to be sufficiently crosslinked or sufficiently cooled so that the second layer structural reinforcement 443 can resist deformation when the second airbag 403 is removed.

[0078] Reference Figure 4I Once the second polymer resin foam 441 has fully cured, in box 316, the second airbag 403 is deflated and removed from the structural component 400, which now includes first layer structural reinforcements 442, 444, 446 in contact with the inner surface 406 of component 408, and a second layer structural reinforcement 443 in contact with the inner surface of component 408 and the first layer structural reinforcements 442, 444, 446. In some aspects, the second airbag 403 can be deflated simply by reducing the pressure of the fluid 429 applied to the second airbag 403 by pumping liquid out of the second airbag 403 or by elastic recovery of the second airbag 403 or an external source. As shown, the second layer structural reinforcements 120, 122, 124, 126, 443 are in various shapes depending on the shape of components 112, 408, the first layer structural reinforcements 442, 444, 446, and the second airbag 403. As described above, after the removal of the second airbag 403, the first and second layer structural reinforcements 442, 443, 444, and 446 define the second hollow channel 130. It should also be understood that additional airbags can be provided, and the above process can be repeated to provide additional structural reinforcement layers.

[0079] References in this article Figure 5 and Figures 6A to 6F Description used to form such Figure 2Other aspects of the method and system for the structural component 103 of the vehicle shown. Method 500 begins at block 502 by inserting an uninflated, insertable first airbag 602 and a second airbag 603, connected to the outer surface 604 of the first airbag 602, into a first hollow channel 606 defined by the inner surface 608 of the component 610 forming the structural component 600. The first airbag 602 includes guide lines 612, 614 connected to and extending from either side of the first airbag 602 to aid in positioning the first airbag 602 within the component 610. The guide lines 612, 614 also include attachment rings 616, 618 for securing the first airbag 602 in place to prevent movement of the first airbag 602 within the component 610 during molding. The attachment rings 616, 618 may be connected to the structural component 600 or to a fixing device that holds the structural component 600 in place during molding. In some respects, the first airbag 602 is formed of silicone resin, polypropylene, polyamide-reinforced polypropylene, or rubber.

[0080] As shown above Figures 4A to 4I Similar to the first airbag 402 described above, the first airbag 602 also includes confined portions 620, 622, and 624, which exhibit less expansion when the first airbag 602 is inflated than the rest of the first airbag 602. The confined portions 620, 622, and 624 are formed in a similar manner and from similar materials to the first airbag 402 described above. Similarly, although three confined portions are shown, any number of confined portions may be provided, for example, from one to ten. Furthermore, it should be understood that although the confined portions are shown extending around the entire periphery of the first airbag 602, the confined portions may be limited to a few segments around the periphery of the airbag. In addition to the confined portions, as described above, inflatable portions may also be provided, exhibiting greater extensibility than the rest of the airbag 602.

[0081] In box 504, refer to Figure 6BThe first airbag 602 inflates by filling it with fluid 628 (e.g., air, inert gas, or liquid) via a supply line 630 connected to the interior 632 of the first airbag 602. This, in turn, inflates the second airbag 603, which is connected to the outer surface 604 of the first airbag 602. As shown, when the first airbag 602 inflates, the second airbag 603 remains unfilled and takes on the shape defined by the first airbag 602. In the illustrated aspect, portions of the first airbag 602 and the second airbag 603 impact and contact the inner surface 608 of the component 610 to define a plurality of first cavities 634, 636, 638 between the outer surface 608 of the component 610 and the two airbags 602, 603. It should be understood that although a plurality of cavities are shown, one cavity or two or more cavities may be defined. In some respects, the temperature of fluid 628 can be adjusted, for example by circulating fluid 628 through a cooler or heater, to facilitate the molding of structural reinforcements by helping to cure or cool the resin subsequently introduced into the first cavities 634, 636, 638.

[0082] After filling airbag 602 in box 504, refer to box 506. Figure 6C The first cavities 634, 636, and 638 are filled with the first polymer resin that forms the first polymer resin foam 640, which produces the first layer structural reinforcements 642, 644, and 646. (Refer to the above.) Figures 4A to 4IIn the described aspect, the first polymer resin releases gas through a chemical reaction to form a first polymer resin foam 640. Alternatively, the first polymer resin foam 640 includes a foaming agent or expandable particles that expand to form the foam. In some aspects, foaming can be triggered by heating the first polymer resin. Examples of the first polymer resin foam 640 include, for example, a partial or partial foam, a thermoplastic material comprising expandable particles or a foaming agent, or a thermoplastic material mixed with gas after melting and before molding. The first polymer resin used to form the first polymer resin foam 640 includes, for example, one or more of the following: polyurethane, epoxy resin, polyisocyanurate, ethylene vinyl acetate, polyolefin, polyolefin-ethylene vinyl acetate blend, polybutylene terephthalate, polycarbonate, polyphenylene ether, polyethylene terephthalate, and acrylonitrile butadiene styrene. As described above, when a given structural component 600 includes multiple structural reinforcements 642, 644, 646, more than one first polymer resin foam 640 may be used. Different first polymer resins can be used to form the first polymer resin foam 640 of each structural reinforcement, or the same first polymer resin with different amounts of blowing agent can be used. Different first polymer resin foams 640 can exhibit different densities or different mechanical properties, including compressive strength and tensile strength. Alternatively, different amounts of polymer resin can be injected into a given cavity to provide polymer resin foams of different densities.

[0083] The first polymer resin forming the first polymer resin foam 640 is introduced by a gating system 650. In some aspects, the gating system 650 is formed in one or more fixtures 652, which can hold the component 610 during molding. In other aspects, the gating system 650 is formed by tubing connectable to the component 610. The component 610 defines a plurality of ports 656, 658, 660, which are connected to first cavities 634, 636, 638 and connectable to the gating system 650 to introduce the first polymer resin of the first polymer resin foam 640 into the first cavities 634, 636, 638 before or after the first polymer resin foaming. Furthermore, the gating system 650 is connected to a first polymer resin supply system 654. In some aspects, the first polymer resin supply system 654 includes one or more of the following: a supply tank, a reservoir, a metering pump, a feeder, an extruder, and a mixer. Furthermore, as described above, each cavity 634, 636, 638 can be connected to its own gating system 650 and polymer resin supply system 654, so that different polymer resins are introduced into each cavity, and the rate at which polymer resin is metered into each cavity can be regulated. Additionally, vents 662, 664, 666 are defined on component 610 and connected to the first cavities 634, 636, 638 to expel air from the first cavities 634, 636, 638 when the first polymer resin is injected into them.

[0084] Alternatively, before filling the first cavities 634, 636, 638, the first polymer resin is melted, the various raw material components of the first polymer resin are mixed, or the first polymer resin is melted and combined with a gas. For example, when a thermoplastic resin is used, the first polymer resin is melted by heating and, in some respects, combined with a gas. In another example, when a two-component polymer resin such as polyurethane or epoxy resin is used, the resin components are mixed. Alternatively, in an alternative manner, the first polymer resin is introduced without pretreatment (e.g., melting, mixing, or combining with a gas), for example, in the case of a one-component polyurethane.

[0085] After the first cavities 634, 636, and 638 are filled with the first polymer resin, the first polymer resin crosslinks or cures within the first cavities 634, 636, and 638 to form a first polymer resin foam 640. For example, when the first polymer resin is a two-component mixture, the polymer resin can crosslink and cure to form the polymer resin foam 640. In other examples, heating the first polymer resin to initiate crosslinking, removing the foaming agent from the molten first polymer resin, or expanding the expandable particles in the molten first polymer resin can cause gas release or expansion, forming the first polymer resin foam 640. When the first polymer resin of the first polymer resin foam 640 is provided as a melt, the foamed first polymer resin can be cooled and cured. It should be understood that the first polymer resin does not need to be fully crosslinked or fully cooled to ambient temperature, but only needs to be sufficiently crosslinked or sufficiently cooled so that the structural reinforcements 642, 644, and 646 can resist deformation when the first airbag 602 is removed.

[0086] Reference Figure 6D Once the first polymeric resin foam 640 has fully cured, in box 508, the method of forming another second layer of structural reinforcement begins by reducing the pressure of the fluid 628 used to inflate the first airbag 602 and filling the second airbag 603, which is connected to the first airbag 602, with the second polymeric resin foam 641. Reducing the pressure of the fluid 628 in the first airbag 602 provides space for the second airbag 603 to expand. As described above, the second airbag 603 defines a second cavity 635 enclosed by its walls, which has remained unfilled until now. The second cavity 635 is filled with the polymeric resin used to form the second polymeric resin foam 641, which forms the second layer of structural reinforcement 643. In some aspects, the second airbag 603 is formed of silicone resin, polypropylene, polyamide-reinforced polypropylene, or rubber. The shape of the second airbag 603 can be manipulated when filling the first airbag 602. It should be understood that although a single second cavity 635 is shown, multiple cavities can be defined.

[0087] Similar to the first-layer structural reinforcements 642, 644, and 646, in some aspects, the second polymer resin releases gas through a chemical reaction to form a second polymer resin foam 641. Alternatively, the second polymer resin foam 641 includes a foaming agent or expandable particles that expand to form the foam. In some aspects, foaming can be triggered by heating the second polymer resin. Examples of the second polymer resin foam 641 include, for example, a partial or partial foam, a thermoplastic material comprising expandable particles or a foaming agent, or a thermoplastic material mixed with gas after melting and before molding. The second polymer resin used to form the second polymer resin foam 641 includes one or more of, for example, polyurethane, epoxy resin, polyisocyanurate, ethylene vinyl acetate, polyolefin, polyolefin-ethylene vinyl acetate blend, polybutylene terephthalate, polycarbonate, polyphenylene ether, polyethylene terephthalate, and acrylonitrile butadiene styrene. As described above, when a given structural component 600 includes multiple structural reinforcements, more than one type of second polymer resin foam 641 may be used. Different second polymer resins can be used to form the second polymer resin foam 641 of each structural reinforcement, or the same second polymer resin with different amounts of blowing agent can be used. Different second polymer resin foams 641 can exhibit different densities or different mechanical properties, including compressive strength and tensile strength. Alternatively, different amounts of polymer resin can be injected into a given cavity to provide polymer resin foams of different densities.

[0088] The second polymer resin forming the second polymer resin foam 641 is introduced through a second runner 651. In some aspects, the second runner system 651 is formed in one or more fixtures 652, by which the component 610 is held. Alternatively or additionally, the second runner system 651 is formed by a tube connectable to the component 610. As shown, the component 610 defines one port 657, or multiple ports. The port 657 can be connected to a second air bladder 603 defining a second cavity 635 to connect the second cavity 635 to the second runner system 651, so as to introduce the second polymer resin of the second polymer resin foam 641 into the second cavity 635 before or after foaming the second polymer resin. Furthermore, the runner system 651 is connected to a second polymer resin supply system 655. In some aspects, the second polymer resin supply system 655 includes one or more of the following: a supply tank, a reservoir, a metering pump, a feeder, an extruder, and a mixer. In some aspects of providing multiple second cavities 635 and multiple second ports 657, each port may be connected to its own polymer resin supply system 655 via its own gating system 651, such that each cavity 635 may be filled with a different material or at a different rate. Furthermore, an vent 663 is defined on the second airbag 603 and connected to the second cavity 635 to expel air from the second cavity 635 when the second polymer resin of the second polymer resin foam 641 is injected into the second cavity 635. It should be understood that, during the formation of the first layer structural reinforcements 642, 644, 646, the second airbag 603 separates the ports 657 and vent 663 used for forming the second layer structural reinforcement 643 from the nearest cavity 638 used for forming the first layer structural reinforcement 646. In addition, when forming the second layer structural reinforcement 643, the second airbag 603 separates the ports 656, 658, 660 and the exhaust ports 662, 664, 666 used to form the first layer structural reinforcement 642, 644, 646.

[0089] Alternatively, as previously described, before filling the second cavity 635, the second polymer resin is melted, the various raw material components of the second polymer resin are mixed, or the second polymer resin is melted and combined with a gas. For example, when a thermoplastic resin is used, the second polymer resin is melted by heating and, in some respects, combined with a gas. In another example, when a two-component polymer resin such as urethane or epoxy resin is used, the resin components are mixed. Alternatively, in an alternative manner, the second polymer resin is introduced without pretreatment (e.g., melting, mixing, or combining with a gas), for example, in the case of a one-component polyurethane.

[0090] After the second polymer resin of the second polymer resin foam 641 fills the second cavity 635, the second polymer resin crosslinks or cures within the second cavity 635. For example, when the second polymer resin is a two-component mixture, the second polymer resin can form crosslinks and cure into the second polymer resin foam 641. In other examples, heating the second polymer resin to initiate crosslinking, removing the foaming agent from the molten second polymer resin, or expanding the expandable particles in the molten second polymer resin can cause gas release or expansion, forming the second polymer resin foam 641. When the second polymer resin of the second polymer resin foam 641 is provided as a melt, the foamed second polymer resin can be cooled and cured.

[0091] Reference Figure 6D and Figure 6E Once the second polymer resin foam 641 has fully cured, in box 510, the first airbag 602 is deflated and removed from the structural component 600, which now includes first layer structural reinforcements 642, 644, and 646 in contact with the inner surface 608 of component 610, and a second layer structural reinforcement 643 contained within the second airbag 603. In some respects, the first airbag 602 can be deflated simply by reducing the pressure of the fluid 628 applied to the first airbag 602 by pumping liquid out of the first airbag 602 or by elastic recovery of the first airbag 602 or an external source. As shown, the first layer structural reinforcements 120, 122, 124, 642, 644, and 646 are in various shapes depending on the shape of components 112, 610, the second airbag 603, and the first airbag 602. The second-layer structural reinforcements 120, 122, 124, 126, and 643 take various shapes depending on the shapes of components 112, 610, and the second airbag 603. As described above, after the first airbag 603 is removed, the first and second-layer structural reinforcements 642, 643, 644, and 646 define the hollow channel 130.

[0092] Figure 6FOne aspect is shown in which the second airbag 603 may include a functionalized layer at the outer 670 of the second airbag 603. In some aspects, the outer 670 of the second airbag 603 comprises a different material from the inner layer 672 of the second airbag 603 connected to the first airbag 602 (not shown). In a further aspect, the outer 670 of the second airbag 603 includes an adhesion promoter layer, such as an adhesive layer, to promote adhesion between the reinforcing layers. Furthermore, in some aspects, the material selected for the outer layer 670 or the inner layer 672 may enhance the mechanical properties, such as flexural stiffness, of the resulting in-situ sandwich structure. This arrangement provides a composite sandwich structure of the second airbag 603 and the second structural reinforcement 643. In some aspects, considerations for selecting the material of the second airbag 603 coincide with considerations for selecting panels in conventional sandwich structures. Furthermore, it should be understood that additional airbag layers may be provided and configured to provide additional structural reinforcement layers.

[0093] References in this article Figure 7 and Figures 8A to 8F Description used to form such Figure 2 Other aspects of the method and system for the structural component 103 of the vehicle shown. Method 700 begins at block 702 with the insertion of an uninflated, insertable first airbag 802 into a first hollow channel 804 defined by the inner surface 808 of the component 810 providing the structural component 800. The first airbag 802 includes an uninflated second airbag 803 located within the first airbag 802. The first airbag 802 includes guide lines 812, 814 removably connected to and extending from either side of the first airbag 802 at connection points 816, 818 to aid in positioning the first airbag 802 within the component 810. The guide lines 812, 814 also include attachment rings 820, 822 for securing the first airbag 802 in place to prevent movement of the first airbag 802 within the component 810 during molding. Attachment rings 820 and 822 may be attached to structural component 800 or to a fixing device that holds structural component 800 in place during molding. In some aspects, the first airbag 802 is formed of silicone, polypropylene, polyamide-reinforced polypropylene, or rubber.

[0094] Like the first airbag 402, the first airbag 802 also includes a confined portion 824, which exhibits less expansion when the first airbag 802 is inflated than the rest of the first airbag 802. The confined portion 824 is formed in a similar manner and from a similar material to the first airbag 402 described above. Similarly, although one confined portion is shown, any number of confined portions may be provided, for example, from one to ten confined portions. Furthermore, it should be understood that although the confined portion is shown extending around the entire periphery of the first airbag 802, the confined portion may be limited to a few segments of the airbag periphery. In addition to the confined portion, as described above, an inflatable portion may also be provided, wherein the inflatable portion exhibits greater extensibility than the rest of the airbag 802.

[0095] In box 704, refer to Figure 8B The first airbag 802 inflates by filling it with fluid 828 (e.g., air, inert gas, or liquid) via a supply line 830 connected to the interior 832 of the first airbag 802. In the illustrated aspect, the first airbag 802 impacts and contacts the inner surface 806 of the component 810 to define one or more first cavities 834 between the inner surface 806 of the component 810 and the first airbag 802. It should be understood that although a single cavity is shown, two or more cavities may optionally be defined. In some aspects, the temperature of the fluid 828 may be adjusted, for example by circulating the fluid through a cooler or heater, to facilitate the molding of the structural reinforcement by aiding in the curing or cooling of the resin subsequently introduced into the first cavity 834.

[0096] After filling airbag 802 in box 704, refer to box 706. Figure 4C The first cavity 834 is filled with the first polymer resin that forms the first polymer resin foam 840, which creates the first layer structural reinforcement 842. (Refer to the above.) Figures 4A to 4IIn the described aspect, the first polymer resin releases gas through a chemical reaction to form a first polymer resin foam 840. Alternatively, the first polymer resin foam 840 includes a foaming agent or expandable particles that expand to form the foam. In some aspects, foaming can be triggered by heating the first polymer resin. Examples of the first polymer resin foam 840 include, for example, a partial or partial foam, a thermoplastic material comprising expandable particles or a foaming agent, or a thermoplastic material mixed with gas after melting and before molding. The first polymer resin used to form the first polymer resin foam 840 includes, for example, one or more of the following: polyurethane, epoxy resin, polyisocyanurate, ethylene vinyl acetate, polyolefin, polyolefin-ethylene vinyl acetate blend, polybutylene terephthalate, polycarbonate, polyphenylene ether, polyethylene terephthalate, and acrylonitrile butadiene styrene. As described above, when a given structural component 800 includes multiple structural reinforcements 842, more than one type of first polymer resin foam 840 may be used. Different first polymer resins can be used to form the first polymer resin foam 840 for each structural reinforcement, or the same first polymer resin with different amounts of blowing agent can be used. Different first polymer resin foams 840 can exhibit different densities or different mechanical properties, including compressive strength and tensile strength.

[0097] The first polymer resin forming the first polymer resin foam 840 is introduced by a runner system 850. In some aspects, the runner system 850 is formed in one or more fixtures 852, on which the component 810 is held. In other aspects, the runner system 850 is formed by a tube connectable to the component 810. The component 810 defines one or more ports 856 that connect to the first cavity 834 and are connectable to the runner system 850 to introduce the first polymer resin of the first polymer resin foam 840 into the first cavity 834 before or after foaming the first polymer resin. Furthermore, the runner system 850 is connected to a first polymer resin supply system 854. In some aspects, the first polymer resin supply system 854 includes one or more of the following: a supply tank, a reservoir, a metering pump, a feeder, an extruder, and a mixer. As previously described, when more than one cavity is provided, each cavity 834 can be supplied by its own runner system 850 and its own polymer resin supply system 854. In addition, an exhaust port 862 is defined on component 810 and connected to the first cavity 834 to expel air from the first cavity 834 when the first polymer resin of the first polymer resin foam 840 is injected into the first cavity 834.

[0098] Alternatively, before filling the first cavity 438, the first polymer resin is melted, its various raw material components are mixed, or the first polymer resin is melted and combined with a gas. For example, when a thermoplastic resin is used, the first polymer resin is melted by heating and, in some respects, combined with a gas. In another example, when a two-component polymer resin such as polyurethane or epoxy resin is used, the resin components are mixed. Alternatively, the first polymer resin may be introduced without pretreatment (e.g., melting, mixing, or combining with a gas), for example, in the case of a one-component polyurethane.

[0099] After the first polymer resin of the first polymer resin foam 840 fills the first cavity 834, the first polymer resin crosslinks or cures within the first cavity 834. For example, when the first polymer resin is a two-component mixture, the first polymer resin can form crosslinks and cure into the first polymer resin foam 840. In other examples, heating the first polymer resin to initiate crosslinking, removing the foaming agent from the molten first polymer resin, or expanding the expandable particles in the molten first polymer resin can cause gas release or expansion, forming the first polymer resin foam 840. When the first polymer resin of the first polymer resin foam 840 is provided as a melt, the foamed first polymer resin can be cooled and cured. It should be understood that the first polymer resin does not need to be fully crosslinked or fully cooled to ambient temperature, but only needs to be sufficiently crosslinked or sufficiently cooled to allow the structural reinforcement 842 to resist deformation.

[0100] Reference Figure 8D Once the first polymer resin foam 840 has fully cured, in box 708, the method for forming another layer of structural reinforcement begins by filling the second airbag 803 with a second polymer resin that forms the second polymer resin foam 841. The second polymer resin foam 841 forms the second layer of structural reinforcement 843.

[0101] Figures 9A to 9C It shows Figures 8A to 8FThe structure of the first airbag 802 and the second airbag 803. In some aspects, the second airbag 803 is formed of silicone resin, polypropylene, polyamide-reinforced polypropylene, or rubber. Similar to the first airbag 802, the second airbag 803 may include one or more confined portions. One or more inflatable portions may also be provided. In the illustrated aspect, the second airbag 803 is located within the first airbag 802 to define a second cavity 835 between the first airbag 802 and the second airbag 804. It should be understood that although a single second cavity 835 is shown, multiple cavities may be defined. In some aspects, the fluid 828 supplied to the first airbag 802 may be used to regulate the temperature of the polymer resin in the second airbag 803, for example by circulating the fluid 828 through a cooler or heater, to facilitate the molding of the structural reinforcement by aiding in the curing or cooling of the resin subsequently introduced into the second cavity 835.

[0102] Similar to the first structural reinforcement 842, in some aspects, the second polymer resin releases gas through a chemical reaction to form a second polymer resin foam 841. Alternatively, the second polymer resin foam 841 includes a foaming agent or expandable particles that expand to form the foam. In some aspects, foaming can be triggered by heating the second polymer resin. Examples of the second polymer resin foam 841 include, for example, a partial or partial foam, a thermoplastic material comprising expandable particles or a foaming agent, or a thermoplastic material mixed with gas after melting and before molding. The second polymer resin used to form the second polymer resin foam 841 includes one or more of, for example, polyurethane, epoxy resin, polyisocyanurate, ethylene vinyl acetate, polyolefin, polyolefin-ethylene vinyl acetate blend, polybutylene terephthalate, polycarbonate, polyphenylene ether, polyethylene terephthalate, and acrylonitrile butadiene styrene. As described above, when a given structural component 800 includes multiple structural reinforcements, more than one type of second polymer resin foam 841 may be used. Different second polymer resins can be used to form the second polymer resin foam 841 for each structural reinforcement, or the same second polymer resin with different amounts of blowing agent can be used. Different second polymer resin foams 841 can exhibit different densities or different mechanical properties, including compressive strength and tensile strength. As an addition or alternative, different amounts of polymer resin can be injected into a given cavity to provide polymer resin foams of different densities.

[0103] The second polymer resin forming the second polymer resin foam 841 is introduced through a second runner 851. In some aspects, the second runner system 851 is formed in one or more fixtures 852, on which the component 810 is held. In other aspects, the second runner system 851 is formed by a tube connectable to the component 810. As shown, the component 810 defines a port 857, or multiple ports connected to the first air bladder 801 and the second cavity 835, connecting the second cavity 835 to the runner system 851 to introduce the second polymer resin of the second polymer resin foam 841 into the second cavity 835 before or after foaming the second polymer resin. Furthermore, the runner system 851 is connected to a second polymer resin supply system 855. In some aspects, the second polymer resin supply system 855 includes one or more of the following: a supply tank, a reservoir, a metering pump, a feeder, an extruder, and a mixer. Alternatively, the second runner system 831 may be provided, and this second runner system may be directly connected to the first air bladder 802 and the second cavity 835. Furthermore, in some aspects, when the second layer structural reinforcement 842 is molded into the second layer second cavity 835, the vent 863 may be defined on and opened on the first airbag 802 to expel air from the second cavity 835 when the second polymer resin of the second polymer resin foam 841 is injected into the second cavity 835. It should be understood that when the first layer structural reinforcement 842 is formed, the first airbag 802 separates the port 857 and outlet 863 for forming the second layer structural reinforcement 843. Additionally, when the second layer structural reinforcement 843 is formed, the second airbag 803 separates the port 856 and outlet 862 for forming the first layer structural reinforcement 842.

[0104] Alternatively, prior to filling the second cavity 835, the second polymer resin is melted, various raw material components of the second polymer resin are mixed, or the second polymer resin is melted and combined with a gas. For example, when a thermoplastic resin is used, the second polymer resin is melted by heating and, in some respects, combined with a gas. In another example, when a two-component polymer resin such as polyurethane or epoxy resin is used, the resin components are mixed. Alternatively, in an alternative manner, the second polymer resin is introduced without pretreatment (e.g., melting, mixing, or combining with a gas), for example, in the case of a one-component polyurethane.

[0105] After the second polymer resin of the second polymer resin foam 841 fills the second cavity 835, the second polymer resin crosslinks or cures within the second cavity 835. For example, when the second polymer resin is a two-component mixture, the second polymer resin can form crosslinks and cure into the second polymer resin foam 841. In other examples, heating the second polymer resin to initiate crosslinking, removing the foaming agent from the molten second polymer resin, or expanding the expandable particles in the molten second polymer resin can cause gas release or expansion, forming the second polymer resin foam 841. When the second polymer resin of the second polymer resin foam 841 is provided as a melt, the foamed second polymer resin can be cooled and cured. It should be understood that the second polymer resin does not need to be fully crosslinked or fully cooled to ambient temperature, but only needs to be sufficiently crosslinked or sufficiently cooled so that the second structural reinforcement layer 843 can resist deformation when the second airbag 803 is removed. Additional structural reinforcement layers can be formed by adding layers to the first airbag 802.

[0106] Reference Figure 8E and Figure 8F Once the second polymer resin foam 841 has fully cured, in box 710, guide lines 812 and 814 separate from the first airbag 802 at attachment points 816 and 818. As shown, the second structural reinforcement members 120, 122, 124, 126, and 843 take various shapes depending on the shape of the first airbag 801 and the second airbag 803. In this respect, the first airbag 802 and the second airbag 803 remain in the structural member 800 and contribute to the first structural reinforcement layer 842 and the second structural reinforcement layer 843.

[0107] Figures 9A to 9C References are shown Figures 8A to 8F The structure of the first airbag 802 and the second airbag 803 used. The first airbag 802 and the second airbag 803 can be formed by a first layer 902 and a second layer 903 made of airbag material, wherein each layer can be formed of the same or different airbag material as described above. As shown, each layer 902, 903 may include confined regions 904, 906, 908, 910 to reduce the expansion of the first airbag 802 and the second airbag 803 in these regions. Additionally or alternatively, expandable regions may be provided in either layer 902, 903. Figure 9A As shown, the first layer 902 and the second layer 903 are stacked together and extend together. However, in some respects, the size of the second layer 903 can be smaller than that of the first layer. For example... Figure 9BAs shown, a first layer 902 and a second layer 903 are fixed together, forming a second airbag 803 between the first layer 902 and the second layer 903. In the illustrated example, the first layer 902 and the second layer 903 are bonded together by heat sealing or adhesive to form a closed region 914 within the periphery 916 of the first layer 902. Alternatively, multiple closed regions 914 may be formed to create multiple second cavities 835 between the first airbag 802 and the second airbag 803. The first airbag 802 is then formed by rolling the first layer 902 and the second layer 903 into a tube 920 and sealing the longitudinal edges 922, 924 of the first layer 902 together. In a further aspect, for example, where the second layer 903 extends co-existing with the first layer 902, the longitudinal edges 926, 928 of the second layer 903 are also sealed together with the longitudinal edges 922, 924 of the first layer 902. In some aspects, the longitudinal edges 922, 924, 926, 928 overlap and are sealed together in an overlapping manner. Figure 9C As shown, at least the first layer 902, and in some respects the ends 930, 932 of the second layer 903, are bundled together and sealed to form the first airbag 802 and the second airbag 803. The first port 856 and the second port 857 for receiving polymer resin can be formed at any time during the formation of the first airbag 802 and the second airbag 803.

[0108] As mentioned above Figure 1B and Figure 1C Further described in Figures 1 to 12 Figure 8F As shown above, the first layer structural reinforcement members 132, 442, 444, 446, 642, 644, 646, and 842 only partially fill the given cross-sections of the first hollow channels 116, 404, 606, and 804 defined by the structural members 103, 400, 600, and 800. Furthermore, the second layer structural reinforcement members 134, 443, 643, and 843 also only partially fill the given cross-sections of the first hollow channels 116, 404, 606, and 804 defined by the structural members 103, 400, 600, and 800, and the second hollow channels defined by the first layer structural reinforcement members 132, 442, 444, 446, 642, 644, 646, and 842.

[0109] While the methods described herein pertain to the B-pillar, it should be understood that these methods can be used to integrate structural reinforcements into other structural components that include or define hollow passageways. Structural components include those that perform at least one of the following functions: supporting vehicle weight, absorbing road impacts, and managing collision energy. Structural components include, for example, various pillars (A, B, C, D) as described above, radiator core supports, front and rear bumper reinforcements, crossbeams, seat frames, front and rear door anti-collision beams, etc. Furthermore, it should be understood that the methods used herein can be used to deposit material in hollow passageways defined by other vehicle components, such as in air ducts.

[0110] Structural components including structural reinforcements and methods for forming such components offer several advantages. Compared to molding methods that require the structural reinforcements to be freely raised and fully filled within the structural component, advantages include, for example, the ability to form multiple structural reinforcements in a single step within the structural component. This results in a reduction in the cycle time for structural components including more structural reinforcements (requiring multiple filling stations). Other advantages include weight reduction due to the ability to partially fill the structural reinforcements within the structural component. This leads to a lighter structural component, contributing to a lighter vehicle.

[0111] The descriptions in this disclosure are merely exemplary in nature, and variations thereof without departing from the spirit and scope of this disclosure are intended to be within its scope. Such variations should not be considered as departing from the spirit and scope of this disclosure.

Claims

1. A method for forming a structural component of a vehicle, comprising: A first cavity is formed within a first hollow channel between the inner surfaces of the first airbag and the component; A first structural reinforcement layer is formed within the first cavity by filling the first cavity with a first polymer resin; The first polymer resin is foamed to form a first polymer resin foam; A second cavity is formed within the first hollow channel, wherein the second cavity is formed by one of the following methods: (i) After the first polymer resin foam is formed, the first airbag is removed from the first hollow channel; after removing the first airbag from the first hollow channel, a second airbag is inserted into the first hollow channel and inflated, the second cavity being formed between the second airbag and the first structural reinforcement layer; or (ii) The second airbag is connected to the outer surface of the first airbag, and when the first airbag is inflated, the second cavity is formed inside the second airbag; or (iii) A second cavity is formed between the first airbag and the second airbag located within the first airbag; A second structural reinforcement layer is formed within the second cavity by filling the second cavity with a second polymer resin; and The second polymer resin is foamed to form a second polymer resin foam.

2. The method according to claim 1, wherein, The first polymer resin foam and the second polymer resin foam partially fill the first hollow channel.

3. The method according to claim 1, wherein, It also includes inflating the first airbag with a first fluid.

4. According to the method described in claim 1, wherein, In the manner of forming the second cavity (i), the second cavity is formed between the second airbag, the first structural reinforcement layer, and the inner surface of the component.

5. The method according to claim 1, in the manner of forming the second cavity (ii), further comprising: The outer surface of the second airbag is adhered to the first structural reinforcement layer.

6. The method according to claim 1, in the manner of forming the second cavity (iii), further comprising: Disconnect the first and second supply lines from the first and second airbags.

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