Bracket for reinforcing vehicle frame and method for manufacturing same

Abstract

The present invention relates generally to a bracket and a method of manufacturing the same, the bracket comprising: a. A periphery having the following components: an outer edge distal of a bracket transverse axis and configured to face away from a frame housing of a vehicle; the inner edge is located on the far side of the transverse shaft and is configured to face a frame shell of the vehicle; and distal ends opposite each other along a longitudinal axis of the carriage; b. One or more series of ribs having a cross-sectional pattern and an orientation along a longitudinal axis and / or a transverse axis.

Description

Technical Field

[0001] The present invention generally relates to an apparatus and method for strengthening a vehicle frame. The apparatus and method may be particularly useful for providing improved crash test performance. Background Art

[0002] It is well known that structural reinforcements may be used to increase the strength of a structural frame. The vehicle frame may be subjected to forces generated by the weight of cargo and passengers, uneven road conditions, collisions, or any combination thereof. Rockers and bumpers are particularly susceptible to side, rear, and front impacts.

[0003] The proliferation of vehicles equipped with hybrid and electric drive systems has placed new demands on vehicle safety. In addition to the expense of replacing damaged batteries after a crash, battery damage can also lead to fires and explosions.

[0004] There is a need for a structural reinforcement that can be used in a rocker and / or bumper. There is a need for a structural reinforcement to protect the battery of the drive system. There is a need for a structural reinforcement that is lightweight and does not significantly increase the overall weight of the vehicle. There is a need for a method of producing a structural reinforcement that can achieve various customization options, including materials, peripheral shapes, arrangement of structural ribs, or any combination thereof. SUMMARY OF THE INVENTION

[0005] The present invention relates to a bracket, which includes: a. a periphery having the following components: an outer edge, which is located on the far side of the bracket's transverse axis and is configured to face away from the frame shell of the vehicle; an inner edge, which is located on the far side of the transverse axis and is configured to face the frame shell of the vehicle; and distal ends opposite to each other along the longitudinal axis of the bracket; b. one or more series of ribs having a cross-sectional pattern and an orientation along the longitudinal axis and / or the transverse axis.

[0006] The present invention relates to a bracket for reinforcing a vehicle frame, the bracket comprising: a. a periphery having the following components: an outer edge located on the far side of the bracket's transverse axis and configured to face away from the frame shell of the vehicle; an inner edge located on the far side of the transverse axis and configured to face the frame shell of the vehicle; and distal ends opposite to each other along the longitudinal axis of the bracket; b. one or more series of ribs having a cross-sectional pattern and an orientation along the longitudinal axis and / or the transverse axis. Wherein, the bracket can reduce the intrusion of the impacting object in the event of a collision.

[0007] The present invention relates to a method for manufacturing a bracket for reinforcing a vehicle frame, the method comprising: extruding, co-extruding or pultruding one or more substrates and / or one or more reinforcing materials to manufacture: a. a periphery having the following components: an outer edge, which is located on the far side of the bracket's transverse axis and is configured to face away from the vehicle's frame shell; an inner edge, which is located on the far side of the transverse axis and is configured to face the vehicle's frame shell; and distal ends opposite to each other along the bracket's longitudinal axis; b. one or more series of ribs having a cross-sectional pattern and an orientation along the longitudinal axis and / or transverse axis.

[0008] The present invention provides a bracket that can be used in a rocker and / or a bumper. The present invention provides a bracket that protects a drive system battery. The present invention provides a bracket that is lightweight and does not significantly increase the overall weight of the vehicle. The present invention provides a bracket that can be made by a method that enables various customization options, including materials, peripheral shapes, placement of structural ribs, or any combination thereof. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 A perspective view of the frame is shown.

[0010] Figure 2 A plan view of the cab is shown.

[0011] Figure 3 A perspective cross-sectional view of the bracket is shown.

[0012] FIG. 4 shows a perspective view of the bracket.

[0013] FIG. 5 shows a cross-sectional view of the rocker with the bracket.

[0014] Figure 6 A plan view of a vehicle subjected to a crash test is shown.

[0015] Figure 7 Shown by Figure 6 The test data curve obtained by the test is shown.

[0016] Figure 8 Shown by Figure 6 The test data curve obtained by the test is shown.

[0017] Fig. 9 is a perspective view of an exemplary bracket resulting from the present invention.

[0018] Fig.10 Yes Fig. 9 A perspective view of the body of the carriage is shown. manual

[0019] The present invention satisfies one or more of the above-mentioned needs through the improved devices and methods described herein. The descriptions and illustrations given herein are intended to familiarize other technical personnel in the field with the present invention, its principles and its practical application. Those skilled in the art can adjust and apply the present invention in various forms to best meet the requirements of specific uses. Therefore, the specific embodiments of the present invention described are not intended to be exhaustive or limit the present invention. Therefore, the scope of the present invention should not be determined with reference to the above description, but with reference to the attached claims and the full range of equivalents enjoyed by these claims. The disclosures of all articles and references, including patent applications and publications, are incorporated herein by reference for various purposes. Other combinations obtained from the following claims are also possible, and these claims are therefore incorporated into this written description by reference.

[0020] The vehicle can enclose and protect the occupants in the event of a collision (i.e., the vehicle is struck by another vehicle or object). The vehicle can be symmetrically divided into a left side (i.e., the driver's side, applicable to vehicles traveling in the United States) and a right side, as well as a front end (including the front bumper) and a rear end (including the rear bumper). The vehicle can be of any traditional type, including a two-door sedan, a four-door sedan, a station wagon, a hatchback, a non-mid-size SUV, a mid-size SUV, a sports utility vehicle, a van, a minivan, a pickup truck, etc. The vehicle can be of any make, model, year, or any combination thereof. The vehicle can be a gasoline-powered vehicle, a battery-powered vehicle, or a hybrid-powered vehicle. The vehicle can include a frame.

[0021] A battery-powered vehicle may include a battery for generating power and transmitting the power to the drive wheels. The battery may be located in any part of the vehicle, including but not limited to under the floor, on top of the floor, under the seat, in the trunk, in the engine compartment, or any combination thereof. The battery may span a single or multiple sections of the vehicle. For example, the battery may be substantially flat, located under the floor, and extending from the left side of the vehicle to the right side of the vehicle, and from the front wheel housing to the rear wheel housing. The battery may be a lithium-ion battery, a nickel metal battery, a lead-acid battery, or a supercapacitor battery. During a collision, the battery may catch fire or explode, wherein the battery may directly contact or be pierced by the collision object, be crushed or pierced by adjacent frame members, be pushed by the impact force, or any combination thereof. For example, damage to a lithium-ion battery may cause the positive electrode to come into direct contact with the negative electrode, thereby causing a short circuit, thereby raising the temperature enough to cause a fire.

[0022] The frame may serve the following functions: serve as a structural frame for the vehicle to accommodate vehicle components (e.g., engine, drive train, doors, seats, etc.), absorb forces generated by collisions, prevent intrusion of colliding objects (e.g., vehicles, sign poles, utility poles, concrete partitions, etc.), protect passengers, protect vehicle components (e.g., engine or battery), or any combination thereof. The frame may be integral with the vehicle body or the vehicle body is on the frame. The frame may include any conventional frame components, including but not limited to front skirts, rear aprons, A-pillars, B-pillars, C-pillars, door sills, rockers, bumper beams, floors, crossbars, or any combination thereof. The frame may define a frame shell, front wheel housings (at the front end of the vehicle), rear wheel housings (at the rear end of the vehicle), or any combination thereof.

[0023] The frame shell can be used to enclose vehicle passengers and vehicle components (e.g., engine, seats, batteries, electronic equipment, etc.). The frame shell can be defined by the surrounding components of the frame. For example, the passenger area can be in a generally trapezoidal prism shape and defined by the A-pillars at the front, the B-pillars at the rear, the floor at the bottom, and the roof rails and roof bows at the top. The frame shell can include the passenger area, the battery tray, the seats, or any combination thereof.

[0024] The passenger area can accommodate a single passenger. The frame shell can include two or more, four or more, ten or fewer, or even eight or fewer passenger areas. For example, a two-seater vehicle can have one passenger area on its left side and one passenger area on its right side. For another example, a four-seater vehicle can have two passenger areas on its left side, one near the front wheel housing and one near the rear wheel housing; and two passenger areas on its right side, one near the front wheel housing and one near the rear wheel housing.

[0025] The battery tray can be used to secure the battery in place, encapsulate the battery, provide a protective barrier for the battery, or any combination thereof. The battery tray can be located within or near the frame housing (e.g., under and near the floor subframe). The battery tray can be located within or near a separate passenger area, or can span multiple passenger areas. For example, the battery tray can be located under the seat of the passenger area adjacent to the rear wheel arch. As another embodiment, the battery tray can span the left and right passenger areas of the vehicle. The battery tray can be located on top of the floor tray, or can be fixed to the frame under the floor tray, or can be fixed to any other frame member. The battery tray can include a single or multiple components. A single-component battery tray can be fixed to the frame of the vehicle to form an enclosure (e.g., a single component fixed to the underside of the floor tray, whereby the battery is completely encapsulated between the floor tray and the single component). The components of a multi-component battery tray can form complementary fits and encapsulate the battery. The battery tray can also accommodate components commonly found in electric drive systems, including but not limited to heaters, controllers, insulators, junction boxes, or any combination thereof.

[0026] The front skirt may be a body panel between the front door and the front end of the vehicle. The front skirt may extend vertically from the hood of the vehicle to the rocker. The front skirt may extend horizontally from the front door of the vehicle to the front end. The front skirt may define a front wheelhouse.

[0027] The tailgate may be a body panel between a rear door and a rear end of a vehicle. The tailgate may extend vertically from a rear window of the vehicle to a rocker. The tailgate may extend horizontally from a rear door to a rear end of the vehicle. The tailgate may define a rear wheelhouse.

[0028] A-pillars, B-pillars, C-pillars, or any combination thereof ("pillars") may be used to support the roof, doors, windows, or any combination thereof. Pillars may be used as complementary pairs, one on the left and one on the right side of the vehicle. The A-pillar may extend upward (i.e., toward the roof) from the front skirt to the roof at an angle. The B-pillar may extend upward from the door sill to the roof. The B-pillar may extend from the door sill at an angle, or may be substantially perpendicular to the door sill. The vehicle may include multiple pairs of B-pillars, wherein the vehicle includes more than two sets of doors. The C-pillar may extend upward from the rear panel at an angle to the roof. The complementary left and right side pillars may substantially define the boundaries of the passenger area. For example, two adjacent passenger areas may be located between the A-pillar and the B-pillar, and two other adjacent passenger areas may be located between the B-pillar and the C-pillar.

[0029] The door sill can be used to strengthen the bottom of the vehicle to prevent it from sinking and intruding into the frame shell in the event of a collision. There can be two door sills, one on the left side of the vehicle and one on the right side of the vehicle. The door sill can include two longitudinal distal ends that span the distance between the front wheelhouse (i.e., the front distal end) and the rear wheelhouse (i.e., the rear distal end). The front distal end can be connected to the front fender and the rear distal end can be connected to the rear panel. A floor (which provides a base and support for the weight of any person or object contained in the frame shell, and the weight can be transferred to the door sill) can be located between the left door sill and the right door sill. The door sill can be configured to resist vertical forces (such as the weight of the roof transmitted to the door sill through the B-pillar) and horizontal forces (such as the horizontal force vector generated by a side impact) without bending. The door sill can be shaped so that the door sill can resist bending stresses from multiple directions. For example, the door sill can be L-shaped so that the door sill can resist bending stresses directed to the distal ends of each leg of the L shape.

[0030] The rocker may be used to increase the strength of the threshold, protect the threshold from corrosion, protect the threshold from impact, provide an aesthetic covering for the threshold, or any combination thereof. There may be two rockers, one for the left threshold and one for the right threshold. The rocker may be configured to form a complementary fit with the threshold. The rocker may include a flange that is configured to abut the threshold approximately flush. The rocker may be secured to the threshold by welding and / or fasteners. The rocker may be removably connected to the threshold for replacement (e.g., when damaged or corroded by impact), and / or a bracket may be introduced. The rocker may comprise a polymer and / or a metal. The fit of the rocker with the threshold may result in the formation of a cavity that may be suitable for accommodating a bracket. The rocker may be configured as an initial contact interface for the colliding objects in the event of a collision.

[0031] The bumper beam may be used to reinforce the front end of a vehicle and / or the rear end of a vehicle. The bumper beam may be configured to prevent an impacting object from intruding into the engine compartment and / or trunk of the vehicle. The bumper beam may be located behind the rear bumper (i.e., rear body panel) and the front bumper (i.e., front body panel). The bumper beam may comprise a polymer and / or a metal. The bumper beam may be a molded component secured to the front end and / or rear end. The bumper beam may have a cavity and / or a groove that may be suitable for accommodating a bracket. The bumper beam may have a face facing outwardly away from the frame shell, the face comprising one or more flat sections and / or one or more curved sections, and may be configured as an initial contact interface for an impacting object in the event of a collision.

[0032] The bracket can be used to strengthen the vehicle frame, absorb collision energy, spread the collision energy over a wider geometry, provide a rigid framework that resists buckling, or any combination thereof. The bracket can be used in the vehicle frame. In particular, the bracket can be used in a rocker and / or a bumper beam. The bracket can have an unequal or substantially equal cross-sectional geometry along the longitudinal axis (i.e., passing through the center of the longest part of the bracket and its direction is substantially parallel to the door sill). The bracket can have an unequal or substantially equal cross-sectional geometry along any transverse axis (i.e., any axis that intersects the longitudinal axis perpendicularly and its direction is not limited to any radial direction). For example, the bracket can have a rectangular cross-section along the transverse axis (i.e., an equal cross-sectional geometry), or can have an L-shaped cross-section along the transverse axis (i.e., an unequal cross-sectional geometry). The geometry along the longitudinal axis and the cross section can correspond substantially to the geometry of the door sill and / or the rocker and / or the bumper beam (which may vary depending on the make, model or year of the vehicle). The bracket may include an outer edge (configured to face away from the frame shell) and / or an inner edge (configured to face the frame shell). The bracket may include a top edge (configured to face toward the top of the vehicle) and a bottom edge (configured to face toward the ground) located between the inner edge and the outer edge. The bracket may include a rear cover and / or a front cover, which are located at the longitudinal distal end of the bracket and are configured to be adjacent to the rear wheel arch and the front wheel arch, respectively. The longitudinal length of the bracket may span the entire rocker or be less than the length of the rocker. For example, the bracket may extend only a distance corresponding to the length of one side of the battery tray (i.e., the bracket is specifically used to strengthen the battery tray). The bracket may include one or more substrates, one or more reinforcing materials, one or more additives, or any combination thereof. The bracket may include a periphery, ribs, an activatable material, or any combination thereof.

[0033] The periphery can be used to surround the ribs. The cross-sectional geometry of the periphery can be circular, triangular, quadrilateral, pentagonal, hexagonal, amorphous or any combination thereof. The geometry of the cross section can at least partially cooperate with the threshold and / or the rocker. For example, the geometry of the cross section can form a substantially complementary fit with the rectangular groove on the rocker. The periphery may not span the entire longitudinal or transverse range of the bracket, which can reduce the material volume, reduce manufacturing complexity, reduce weight, save costs, or any combination thereof. The periphery may exceed the longitudinal or transverse range of the bracket, or may be within the longitudinal or transverse range of the bracket. For example, the periphery may only exist on the outer edge and inner edge of the bracket, but not on the top edge and bottom edge of the bracket (i.e., exposing one or more ribs), which can reduce the amount of material required to produce the bracket. The periphery may have gaps in the inner edge, outer edge, top edge, bottom edge, back cover, front cover or any combination thereof. These gaps may be formed on a portion of the periphery, where the ribs do not intersect with the inner portion of the periphery. For example, the periphery may have thin strips of voids along the outer edge, the inner edge, the top edge, the bottom edge, or any combination thereof. The periphery may include an inner surface that interfaces with the ribs and an outer surface that is opposite the inner surface. The thickness of the periphery (i.e., the distance between the inner surface and the outer surface) may be about 0.5-2 mm. The outer surface of the periphery may have a texture. For example, the outer surface may include a notch that extends into the periphery to a certain depth and protrudes along the longitudinal axis of the bracket.

[0034] The one or more series of ribs can be used to absorb energy and protect the frame from deformation caused by collision. Ribs can inhibit bending and / or torsion. The one or more series of ribs can protrude from one or more inner surfaces of the periphery and extend between them. Each of the one or more series of ribs can include one or more ribs. The one or more series of ribs can be located between adjacent vertical surfaces and / or relatively parallel surfaces of the periphery. The one or more series of ribs of the same series can be parallel to each other. The one or more series of ribs of the discrete series can cross each other. The one or more series of ribs of the discrete series can cross each other at any angle. The one or more series of ribs of the discrete series can intersect with some but not all of the ribs of another series. For example, a first series of ribs including six ribs can protrude from the top edge and the bottom edge and extend between them, while a second series of ribs can protrude from the inner edge, perpendicular to the orientation of the first series of ribs, and extend only to the fourth rib in the first series of ribs (i.e., not fully extending to the outer edge). The thickness of the ribs can be about 0.5-2cm. The ribs can be configured with a cross-sectional pattern and orientation. The ribs can include a rigid portion and / or a ductile portion.

[0035] Activatable materials can be used for blocking, sealing, structural reinforcement or any combination thereof. The bracket can be used with or without an activatable material. The activatable material may span a cavity in the structure (e.g., the area between the rocker and the door sill) after curing. The activatable material can be activated to cure, expand (e.g., foam), soften, flow or any combination thereof. The activatable material can be directly applied and usually adhered to the periphery of the bracket. The activatable material can cover most of the surface area of ​​the bracket periphery (e.g., at least 40%, 60%, 80% or more). A variety of activatable materials can be used in combination with the bracket. The activatable material can be formed by a heat-activated material and can flow, cure (e.g., heat-curable), foam or any combination thereof when heated. The activatable material is usually dry to the touch and is substantially non-tacky, or can be tacky, and in either case can be formed into any form of desired pattern, in a certain position or with a certain thickness, but preferably has substantially the same thickness. Exemplary heat-activated activatable materials include L-5520, L-5505, L-5540, L-5905, L-5920, L-5904, L-5235, L-5236, and L-5244 foams, which are commercially available from L&L Products, Inc. Another exemplary activatable material is disclosed in U.S. Pat. No. 7,199,165, which is incorporated herein by reference for all purposes.

[0036] The cross-sectional pattern may be defined by the cross-sectional shape of the rib, wherein the cross-sectional shape refers to the longitudinal cross-sectional shape or the transverse cross-sectional shape of the bracket. The cross-sectional pattern may be a skewed pattern, a rectangular pattern, a honeycomb pattern, a mixed pattern, or any combination thereof. The cross-sectional pattern may be defined by the spatial arrangement and / or angular arrangement of one or more series of ribs. The cross-sectional pattern may include one or more cross-sectional patterns in a single bracket. For example, a skewed pattern may span half of the bracket, while a rectangular pattern may span the other half of the bracket. The cross-sectional pattern may span the entire range of the bracket cross-sectional shape, or may span only a portion of the frame cross-sectional shape. For example, one or more series of ribs forming the cross-sectional pattern may only exist on one cross-sectional half of the bracket, and not on another cross-sectional half of the bracket. The cross-sectional pattern may have a uniform size across the entire range of the bracket cross-sectional shape, or may have a non-uniform size across only a portion of the bracket cross-sectional shape. For example, a bracket may include a rectangular pattern, wherein one cross-sectional half of the bracket includes a rectangular segment of a first size, while another cross-sectional half of the bracket includes a rectangular segment of a second size (e.g., half of the width of the first size).

[0037] The skew pattern may be an arrangement where the one or more series of ribs are skewed from the back cover, front cover or periphery at a certain angle. The skew angles of the one or more series of ribs may be equal and opposite (e.g., -25° and +25°) or asymmetric (e.g., -25° and +15°).

[0038] The rectangular pattern may be that the one or more series of ribs are arranged parallel to the back cover, the front cover or the periphery. The rectangular pattern may be that the first series of ribs in the one or more series of ribs is perpendicular to the second series of ribs therein.

[0039] The honeycomb pattern may be an arrangement of one or more series of ribs, comprising: a first series of ribs having a symmetrical zigzag pattern; a second series of ribs having a symmetrical zigzag pattern having reflection symmetry relative to the first series of ribs; and a third series of ribs parallel to the back cover, front cover or periphery, extending from the peaks formed by the zigzag patterns of the first and second series of ribs.

[0040] The hybrid pattern may be an arrangement of one or more series of ribs according to a combination of a skewed pattern, a rectangular pattern, a honeycomb pattern, or any combination thereof. For example, the ribs may include: a first series of ribs arranged vertically (in a rectangular pattern), a second series of ribs arranged horizontally (in a rectangular pattern), and a third series of ribs deviating from the vertical arrangement (in a skewed pattern). As another example, injection molding may provide a honeycomb pattern protruding along the horizontal axis of the bracket and a rectangular pattern protruding along the longitudinal axis of the bracket and perpendicularly intersecting the honeycomb pattern (i.e., the rectangular pattern includes a single rib formed by the space between the two halves of the injection mold).

[0041] The orientation can be defined by the cross-sectional orientation of the pattern. The orientation can be longitudinal, transverse or angled. The longitudinal orientation can be defined by the cross-sectional orientation of the pattern extending parallel to the longitudinal axis of the carriage and the ribs protruding along the transverse axis of the carriage. The transverse orientation can be defined by the cross-sectional orientation of the pattern extending parallel to the transverse axis of the carriage and the ribs protruding along the longitudinal axis of the carriage. The angled orientation can be defined by the cross-sectional orientation of the pattern deviating from the longitudinal axis of the carriage and / or the transverse axis of the carriage.

[0042] The rigid part can be used to withstand the bending of the bracket. The rigid part can include one or more substrates that exhibit sufficient rigidity in the original state and / or obtain or enhance rigidity by being filled with one or more reinforcing materials. The rigid part can be located on the following as a whole: a single rib in a single series, multiple ribs in a single series, one or more series of ribs, or the periphery. The rigid part can be located on the following parts: a single rib in a single series, multiple ribs in a single series, one or more series of ribs, or the periphery. The rigid part can include the entire bracket.

[0043] The tough portion may deform, thereby absorbing energy. The tough portion may include one or more substrates that exhibit sufficient toughness in their original state and / or obtain or enhance toughness by being filled with one or more reinforcing materials. The tough portion may be located on the entirety of: a single rib in a single series, multiple ribs in a single series, one or more series of ribs, or the periphery. The tough portion may be located on the following parts: a single rib in a single series, multiple ribs in a single series, one or more series of ribs, or the periphery. The tough portion may include the entire bracket.

[0044] In some applications, two or more brackets may be used on a single rocker of a vehicle. The two or more brackets may individually include a rigid portion and a tough portion, or each of the two or more brackets may be rigid or tough as a whole (i.e., a "rigid bracket" or a "tough bracket"). Rigid brackets and tough brackets may be used in combination to obtain enhanced crash test performance. For example, a tough bracket may be used on the side of the rocker facing away from the vehicle, and a rigid bracket may be used on the adjacent side of the rocker facing the vehicle; the tough bracket may be configured to absorb the initial force of the impact and reduce the force ultimately transmitted to the rigid portion; the rigid portion may be configured to resist buckling (i.e., bending stress). Any number of rigid brackets, tough brackets, or any combination thereof may be used. For example, the following components may be stacked horizontally adjacent on the rocker: a first tough bracket, a first rigid bracket, a second tough bracket, and a second rigid bracket.

[0045] When two or more brackets are employed, the brackets may include one or more ribs having different cross-sectional patterns and orientations. For example, a bracket including ribs having a rectangular pattern and a longitudinal orientation may be used in combination with a bracket including ribs having a honeycomb pattern and a transverse orientation. One or more brackets may include ribs having any cross-sectional pattern and orientation described herein. The use of two or more brackets may allow for a combination of homogeneous brackets and / or composite brackets. For example, a homogeneous bracket comprising steel may be paired with a composite bracket comprising fiberglass and polyamide. The use of two or more brackets having substrates and / or reinforcing materials of different compositions may result in a combination of materials, thereby achieving properties that are not typically achievable when manufacturing a single bracket.

[0046] When two or more brackets are used, the brackets may or may not be secured together. The brackets may be secured by adhesive, welding or fasteners.

[0047] The ribs and / or periphery may comprise a composite material consisting of one or more substrates and / or one or more reinforcing materials. The composite material may be layered or homogeneous. The layered composite material may comprise two or more discrete layers, and each discrete layer may be rigid and / or tough. These layers may comprise adhesives, sealants, tapes, and the like for connecting materials of the composite layer. Such adhesive and / or sealing materials may also be used to make a tougher material adjacent to a more rigid and / or more brittle (e.g., less tough) material. For example, by a coextrusion process, a polymer with a lower rigidity (e.g., polyethylene) may be layered with a polymer with a higher rigidity (e.g., polyamide). A less rigid adhesive may be layered with a more rigid adhesive. A uniformly dispersed composite material may comprise two or more components that are substantially uniformly distributed throughout the ribs and / or periphery. For example, by a pultrusion process, glass fibers may be coated with a polymer (e.g., polyamide) so that the glass fibers are uniformly distributed within the polymer.

[0048] The bracket may include one or more substrates. The bracket may include polymers and / or metals. The polymer may include polyamide (PA), polyvinyl chloride (PVC), polyetherimide (PEI), polycarbonate (PC), polymethyl methacrylate (PMMA), acrylonitrile-butadiene-styrene (ABS), polyetherketoneketone (PEKK), polyaryletherketone (PAEK), polyetheretherketone (PEEK), polyphenylene sulfide (PPS), polyethylene terephthalate (PET), polypropylene (PP), polyethylene (PE), or any combination thereof. The metal may include aluminum, steel, brass, magnesium, zinc, titanium, metal alloys, or any combination thereof. The weight percentage content of the one or more substrates in the bracket may be about 1% to 70%. The bracket may include a single substrate (referring to a homogeneous bracket) or multiple substrates (referring to a composite bracket).

[0049] The one or more reinforcing materials can be used to enhance the performance of the bracket, such as increasing tensile strength, increasing bending strength, distributing energy within the reinforcing material, or any combination thereof. The reinforcing material can include mineral reinforcements, glass reinforcements, carbon reinforcements, polymer reinforcements, elastomeric reinforcements, core-shell polymers, or any combination thereof. The one or more reinforcing materials can be present in the bracket in an amount of about 0% to 70% by weight.

[0050] The mineral reinforcement can be any suitable silicate mineral, including but not limited to inosilicates (e.g., wollastonite) and phyllosilicates (e.g., kaolinite, vermiculite, talc, muscovite, etc.), diatomaceous earth, clays (e.g., nanoclays), silicon oxide, calcium, or any combination thereof. The characteristic external shape of a single crystal or a group of crystals of a silicate mineral can be needle-like. The median particle size of the silicate mineral can be about 10-20 μm or 12-18 μm.

[0051] The glass reinforcement may be selected from glass fibers, glass beads, or glass bubbles ("microspheres"). The glass reinforcement may include aluminoborosilicate glass (E glass), soda lime glass (A glass or C glass), electrically / chemically resistant glass (E-CR glass), borosilicate glass (D glass), aluminosilicate glass (R glass or S glass), or any combination thereof. The glass reinforcement may be chopped fibers. The length of the chopped fiber glass reinforcement may be about 0.1 cm or more, 0.3 cm or more, or even 0.6 cm or more. The length of the chopped fiber glass reinforcement may be about 2.0 cm or less, 1.5 cm or less, or even 1.0 cm or less.

[0052] The carbon reinforcement may include carbon fibers or woven fabrics. The carbon reinforcement may be 1K, 2K, 3K, 4K, 5K or even 6K (1K means there are 1000 fiber filaments in a bundle) carbon reinforcement.

[0053] The polymer reinforcement may include fibers of polyamide (e.g., nylon, polyamine, polyphthalamide, or aramid), polypropylene (PP), polyurethane (PUR), polyvinyl chloride (PVC), acrylonitrile butadiene styrene (ABS), polystyrene (PS), polyethylene (PE), polyoxymethylene (POM), polycarbonate (PC), acrylic (PMMA), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), acrylonitrile styrene acrylate (ASA), or any combination thereof. The polymer reinforcement may be fibers having an aspect ratio of about 20:1 to 3:1.

[0054] The elastomeric reinforcement may include natural rubber, styrene-butadiene rubber (SBR), polyisoprene, polyisobutylene, polybutadiene (PBd), isoprene-butadiene copolymers, chloroprene rubber, nitrile rubber (e.g., nitrile such as carboxyl-terminated nitrile), butyl rubber, carboxyl-terminated polymers (e.g., carboxyl-functional butadiene-acrylonitrile), carboxyl-terminated polymers (e.g., carboxyl-functional butadiene-acrylonitrile), polydisulfide polymers, acrylic elastomers, acrylonitrile elastomers, silicone rubber, polysiloxanes, polyester rubbers, diisocyanate-linked condensation elastomers, ethylene-propylene-diene rubber (EPDM), chlorosulfonated polyethylene, fluorinated hydrocarbons, or any combination thereof.

[0055] The core-shell polymer may comprise a first polymer material (i.e., core material) and a second polymer material (i.e., shell material). The first polymer material may be substantially or completely encapsulated by the second polymer material. The shell material may be grafted onto the core material. The weight percentage content of the first polymer material in the core-shell polymer may be about 30% or more, 50% or more, or even 70% or more. The first polymer material and / or the second polymer material may comprise one, two, three or even more polymers that are combined and / or reacted together (e.g., sequential polymerization); or the first polymer material and / or the second polymer material may be separate or part of the same core-shell polymer system. The core-shell polymer preferably has a tough core and a rigid shell. The shell material may have good adhesion to other components of the bracket. The particle size of the core-shell polymer may be about 50–300 nm.

[0056] Examples of shell materials include, but are not limited to, styrene, acrylonitrile, alkyl acrylates (eg, methyl acrylate, methyl methacrylate), vinyl acetate, vinyl chloride, or any combination thereof.

[0057] Examples of core materials include, but are not limited to, polybutadiene (PBd), butyl acrylate, isobutyl ethyl ester, alkyl acrylate (e.g., 2-ethylhexyl) or any combination thereof. The core material may include a copolymer (e.g., a copolymer of styrene, vinyl acetate, methyl methacrylate, butadiene or isoprene). The core material may include a crosslinking monomer (e.g., ethylene glycol diacrylate or butanediol dimethacrylate). The core material may include a grafting monomer (e.g., diallyl maleate or allyl methacrylate).

[0058] The bracket may include one or more additives. The one or more additives may include a foaming agent, a foaming accelerator, a curing agent, a curing accelerator, a filler, a pigment, or any combination thereof.

[0059] Methods of producing the bracket may include injection molding, extrusion, co-extrusion, pultrusion processes, or any combination thereof.

[0060] The bracket can be made by injection molding process. Injection molding can be suitable for producing homogeneous brackets or composite brackets. Homogeneous brackets can be obtained by injection molding of a substrate. Composite brackets can be obtained by injection molding of one or more substrates and one or more reinforcing materials or two or more substrates. The injected material can be a uniform mixture of one or more substrates and one or more reinforcing materials. For example, polyamide can be mixed with glass fiber reinforcement before being injected into the mold. As another embodiment, a single cylinder can deliver a first substrate to a mold cavity, and then a second substrate can be delivered to the mold cavity, so that the first substrate is pushed to the periphery of the mold cavity by the second substrate, thereby allowing the second substrate to be located in the near area of ​​the mold cavity (i.e., layered distribution). As another embodiment, in a dual cylinder system, the first cylinder delivers the first substrate to one distal end of the mold cavity, and the second cylinder delivers the second substrate to the other distal end of the mold cavity, resulting in the first substrate and the second substrate being basically divided into two equal parts (i.e., partitioned distribution). Any combination of the above techniques can be used to obtain a bracket consisting of any combination of one or more substrates and / or one or more reinforcing materials distributed in various layered and / or partitioned ways.

[0061] Since the bracket is removed axially from the mold, injection molding can be suitable for obtaining a bracket lacking part or all of the inner edge, outer edge, top edge, bottom edge, back cover, front cover or any combination thereof. Injection molding can be suitable for obtaining a bracket with longitudinal ribs or transverse ribs. The ribs can be offset from the axis along which the bracket is removed from the mold by a certain angle (i.e., the draft angle) so that the bracket can be easily removed from the mold. Injection molding can be suitable for producing a bracket with a single rib perpendicular to another series of ribs.

[0062] The bracket can be made by an extrusion process. The extrusion process can be suitable for producing homogeneous or composite products. A continuous piece can be produced by the extrusion process, which is then cut into segments after exiting the die to form a single bracket. A homogeneous product can be obtained by extruding a substrate. For example, an aluminum bracket can be obtained by extruding aluminum. A composite product can be obtained by extruding one or more substrates and one or more reinforcing materials. The extruded material can be a uniform mixture of one or more substrates and one or more reinforcing materials. For example, polyamide can be mixed with glass fiber reinforcement before extrusion. The extruded material can be a combination of two or more substrates. For example, the first material and the second material can be fed into the flow channel before exiting (i.e., coextrusion) through the die, thereby allowing the bracket to have a partitioned distribution of the first material and the second material. The coextrusion process can be used to obtain one or more, two or more, eight or less, or even seven or less substrate layers. Any combination of the above techniques can be used to obtain a bracket consisting of any combination of one or more substrates and / or one or more reinforcing materials distributed in various layered and / or partitioned ways.

[0063] Since the bracket moves through the die, the extrusion process can be suitable for obtaining a bracket lacking part or all of the inner edge, outer edge, top edge, bottom edge, back cover, front cover or any combination thereof. In particular, the extrusion process can be suitable for producing a bracket with transversely oriented ribs and without a back cover and / or front cover.

[0064] The bracket can be made by a pultrusion process. The pultrusion process can be suitable for producing composite products. A continuous piece can be produced by the pultrusion process, which is cut into segments immediately after exiting the die to form individual brackets. The pultrusion process can be used in combination with rovings, fabrics (such as unidirectional fabrics, woven fabrics, multi-axial fabrics or randomly oriented fabrics (chopped strand mats)) or films. The pultrusion process can include passing one or more substrates and / or one or more reinforcing materials through an impregnation tank of one or more substrates before using the mold to form the materials. For example, a glass fiber roving can be passed through a polyamide impregnation tank and then guided through a mold with cantilevered mandrels that form gaps between ribs. Any combination of the above techniques can be used to obtain a bracket composed of any combination of one or more substrates and / or one or more reinforcing materials distributed in various layered and / or zoned manners.

[0065] Since the bracket moves through the die, the pultrusion process can be applied to obtain a bracket lacking part or all of the inner edge, outer edge, top edge, bottom edge, back cover, front cover or any combination thereof. In particular, the pultrusion process can be applied to produce a bracket with transversely oriented ribs and without a back cover and / or front cover.

[0066] The bracket may include a first portion formed by an injection molding process and a second portion formed by a pultrusion process. The pultrusion process may utilize a first polymer that may be a polyurethane material. The first portion may be injection molded (e.g., overmolded) around the second portion. Alternatively, the first portion may be mechanically or adhesively fixed to the second portion. The first portion may be formed as a single integral structure, or may be composed of multiple parts. These multiple parts may be adhesively or mechanically attached to the second portion. The second portion may be formed as an integral insert. The profile of the insert may be generally u-shaped or rectangular. The first portion may include one or more rib structures that may be substantially perpendicular to the longitudinal axis of the bracket. The one or more rib structures may extend along the entire bracket. The second portion may be substantially surrounded by the one or more rib structures, thereby forming a row of rib structures on at least two sides of the insert. An adhesive may be applied to one or more of the first portion or the second portion. The adhesive may be applied by an inline process. The adhesive material may be extruded onto the bracket. The bracket may replace an aluminum rocker and provide a reinforcement effect comparable to that of an aluminum rocker, but weighs significantly less than an aluminum rocker. The bracket may be located within a vehicle cavity.

[0067] The performance of the brackets of the present invention can be determined and compared by performing crash tests. Crash tests can be simulated (i.e., by computer modeling) or conducted in situ (i.e., using actual vehicles). Crash tests may involve a test vehicle colliding with a collision object (e.g., a pole), wherein the collision object is stationary and the vehicle moves toward the collision object at a fixed speed, or vice versa. Intrusion can be the entry of the collision object into the vehicle body, and displacement can be a measurable degree of intrusion (i.e., the distance between the far plane of the vehicle before the collision and the plane tangent to the deepest intrusion point). Performance can be determined by the peak displacement (i.e., the deepest intrusion point) and / or the constant force displacement (i.e., the deepest intrusion point at a given measurable force) of the collision object. Due to the elasticity of the vehicle and / or the collision object, the peak intrusion amount may not correspond to the intrusion amount when the vehicle or collision object is no longer moving. Measuring the constant force displacement can provide a meaningful comparison between two test embodiments (e.g., an embodiment of the present invention and a comparative embodiment), because the peak force between the two test embodiments may vary due to variable force absorption characteristics (e.g., a lower peak force may be recorded for a vehicle with a bracket compared to a vehicle without a bracket).

[0068] Table 1 shows the peak displacement and fixed force displacement of the comparative embodiment (i.e., the vehicle without the bracket) and the embodiment of the present invention (i.e., the vehicle with the bracket of the present invention). The CAE model was used to measure the vehicle traveling at a speed of 32 km / h toward the collision object (i.e., the inclined pole with an angle of about 75°), and the collision point was close to the passenger area on the front driver's side and toward the center of the battery tray, as shown in FIG. Figure 2 The vehicles in the embodiment of the present invention and the comparative embodiment have similar structures, which correspond to Figure 2 The structure shown. Figure 6 A plan view of a vehicle undergoing a crash test is shown.

[0069] Table 1

[0070] Figure 1 A perspective view of the frame 20 is shown. The frame 20 includes a left side 12A facing away from the viewer and a right side 12B facing the viewer. The frame 20 includes a front end 14A and a rear end 14B. The frame 20 includes a sill 24, a front skirt 34 adjacent to the sill 24, and a rear panel 36. The front skirt 34 defines a front wheel housing 28A, and the rear panel 36 defines a rear wheel housing 28B. The sill 24 is horizontally located between the front wheel housing 28A and the rear wheel housing 28B. The frame 20 includes an A-pillar 26A, a B-pillar 26B, and a C-pillar 26C. The A-pillar 26A extends upward at an angle from the front skirt 34, the B-pillar 26B extends upward flat from the sill 24, and the C-pillar 26C extends upward at an angle from the rear panel 36. The frame also includes a bottom plate 30. The frame 20 defines a frame housing 50.

[0071] Figure 2A plan view of a passenger area 52 is shown, which is a portion of the frame housing 50 and is located on the left side 12A of the frame 20 and adjacent to the front wheel housing (not shown). The passenger area 52 includes a battery tray 54 and a floor 30. The battery tray 54 includes six battery crossbars 56 arranged at regular intervals within the battery tray 54. The crossbar 32 spans the floor 30 and extends from the left side 12A to the right side (not shown) and intersects the door sill 24 perpendicularly. The door sill 24 extends adjacent to the battery tray 54 and the floor 30. The rocker 22 is fixed to the door sill 24 and spans its length. Figure 2 The position of the impact object 150 in the impact test described herein is shown.

[0072] Figure 3 A perspective cross-sectional view of a bracket 60 is shown. The bracket 60 includes a periphery 62. A cutout of one of the peripheries 62 reveals ribs 64, which include a first series of ribs 64A and a second series of ribs 64B. The ribs 64 are arranged along a transverse orientation 80B. Line AA indicates a longitudinal cross section. Line BB indicates a transverse cross section.

[0073] Fig. 4 shows a perspective view of bracket 60.Bracket 60 comprises outer edge 62A, inner edge 62B, top edge 62C, bottom edge 62D and rib 64.Outer edge 62A is configured to face away from frame housing (not shown), and inner edge 62B is configured to face frame housing (not shown).Rib 64 comprises first series of ribs 64A and second series of ribs 64B that deviate from outer edge 62A and inner edge 62B.First series of ribs 64A are arranged parallel to each other, and second series of ribs 64B are also arranged parallel to each other.Ribs 64 demonstrate transverse orientation 80B and skew pattern 90A.Skew pattern 90A can be observed from the positive projection of the cross section (which means transverse orientation 80B) of bracket 60.

[0074] Figure 5A A cross-sectional view of the bracket 60 is shown. The rocker 22 is secured to the door sill 24 at two seams 25, 25', and the bracket 60 is enclosed between the seams 25, 25'. The rib 64 exhibits a transverse orientation 80B and a skewed pattern 90A. The rib 64 and the periphery 62 comprise a substrate M1.

[0075] Figure 6 A plan view of a vehicle 10 undergoing a crash test is shown, wherein the vehicle 10 is impacted by a collision object 150 (shown as a vertical rod). The point of impact when the vehicle 10 impacts the collision object 150 is located near the passenger area 52, and the impact direction is such that the instantaneous force applied upon impact is characterized by a vector along the force axis 100. The pre-collision plane 102 is substantially flush with the original uncollided frame (not shown) of the vehicle 10. The post-collision plane 104 is defined by a tangent line at the maximum displacement point of the frame (not shown) and is parallel to the pre-collision plane 102. The distance between the two planes 102, 104 is defined as the displacement 106.

[0076] Figure 7 Shown by Figure 6 The collision test data curve obtained by the test is shown. Comparative embodiment 130 (i.e., a rocker without the bracket (not shown) of the present invention) is shown together with embodiment 132 of the present invention (i.e., a rocker with the bracket (not shown) of the present invention). Each curve reaches a peak value along the Y axis, i.e., peak displacement 110, 110'. The peak displacement 110 of the comparative embodiment is greater than the peak displacement 110' of the embodiment of the present invention, proving that the anti-intrusion effect is improved by adopting the bracket (not shown) of the present invention.

[0077] Figure 8 Shown by Figure 6 The crash test data curve obtained from the test is shown. Comparative Example 130 (i.e., a rocker without the bracket of the present invention (not shown)) is shown together with the present example 132 (i.e., a rocker with the bracket of the present invention (not shown)). Each sample 130, 132 achieves a peak force 112, 112' and a peak displacement 110, 110'.

[0078] Fig. 9 A bracket 60 is shown. The bracket includes a plurality of transverse ribs 64. The transverse ribs are located along a first portion 134 of the bracket, the first portion 134 comprising a polyamide (e.g., supertough polyamide 6) as a first material M1. The bracket 60 also includes a second portion 136, the second portion 136 including an insert 138 formed of a polyurethane material M2 (different from the material M1 of the first portion 134 of the bracket). Adhesive 140 is applied along an edge portion 142 of the insert 138. The insert 138 is pultruded, and the first portion of the bracket 134 and the plurality of ribs 64 are injection molded around the insert 138.

[0079] exist Fig.10 middle, Fig. 9 The bracket 60 is positioned along the rocker 22 , the plurality of transverse ribs 64 extend along the long section of the rocker 22 , and the insert 138 also extends along the long section of the rocker 22 .

[0080] Any numerical value listed in the above application includes all values ​​from the lower limit to the upper limit in increments of one unit, provided that there is at least a 2-unit interval between any lower limit and any upper limit. These are only embodiments of specific intent, and it is believed that all possible numerical combinations between the lowest and highest values ​​listed are clearly stated in this application in a similar manner. All ranges include all numerical values ​​between endpoints, unless otherwise stated.

[0081] The terms "generally" or "substantially" used to describe angular measurements may mean a range of approximately + / -10° or less, + / -5° or less, or even + / -1° or less. The terms "generally" or "substantially" used to describe angular measurements may mean a range of approximately + / -0.01° or more, + / -0.1° or more, or even + / -0.5° or more. The terms "generally" or "substantially" used to describe linear measurements, percentages, or ratios may mean a range of approximately + / -10% or less, + / -5% or less, or even + / -1% or less. The terms "generally" or "substantially" used to describe linear measurements, percentages, or ratios may mean a range of approximately + / -0.01% or more, + / -0.1% or more, or even + / -0.5% or more.

[0082] The phrase "consisting essentially of..." used to describe a combination shall include the identified elements, ingredients, components or steps, as well as other elements, ingredients, components or steps that do not materially affect the basic and novel characteristics of the combination. When "including" or "comprising" is used herein to describe a combination of elements, ingredients, components or steps, an embodiment consisting essentially of these elements, ingredients, components or steps is also considered.

[0083] Multiple elements, components, parts or steps may be provided by a single integrated element, component, part or step. Alternatively, a single integrated element, component, part or step may be divided into separate multiple elements, components, parts or steps. The reference to "a" or "an" when describing an element, component, part or step is not intended to exclude additional elements, components, parts or steps.

Claims

1. A bracket for strengthening a frame of a vehicle, comprising: a. The first part has: i. an inner side, which is configured to face the frame shell close to the vehicle; as well as ii. a first end and a second end opposite to each other along the longitudinal axis of the bracket; b. A second portion adjacent to the first portion, the second portion having: i. an outer side configured to face away from the frame shell of the vehicle, wherein the outer side is opposite and spaced apart from the inner side along the transverse axis, and wherein the outer side is configured further away from the frame shell than the inner side; ii. a first end and a second end opposite to each other along the longitudinal axis of the bracket; wherein the first portion and the second portion each include a first series of ribs and a second series of ribs, the first series of ribs and the second series of ribs forming a rectangular cross-sectional pattern and extending perpendicular to the longitudinal axis; wherein, in both the first portion and the second portion, the first series of ribs have a vertical orientation and the second series of ribs have a horizontal orientation perpendicular to the vertical orientation; wherein, in both the first portion and the second portion, the rectangular cross-sectional pattern forms a plurality of rectangles aligned to form a plurality of rows and columns; wherein, in the first portion, the first series of ribs and the second series of ribs are located within a periphery of the first portion, the periphery being defined between a first end and a second end and an inner side of the first portion; and Wherein, in the second portion, the first series of ribs and the second series of ribs are located within a periphery of the second portion, the periphery being defined between the first and second ends and an outer side surface of the second portion.

2. The bracket according to claim 1, wherein: The rectangular cross-sectional patterns of the first and second portions span the entire length of the first and second portions, respectively, and The length is the distance between the first end and the second end of the first part and the second part respectively.

3. The bracket according to claim 1, wherein: The first and second portions are joined at an area comprising additional ribs, the additional ribs being perpendicular to the first and second series of ribs and extending parallel to the longitudinal axis of the bracket.

4. The bracket according to claim 3, wherein: The additional rib divides the bracket into two.

5. The bracket according to claim 1, wherein: The first portion and the second portion are formed as a single unitary construction, or the first portion is mechanically or adhesively secured to the second portion.

6. The bracket according to claim 1, wherein: The bracket is used in a frame of the vehicle.

7. The bracket according to claim 6, wherein: The bracket is located between a rocker and a door sill of the vehicle's frame.

8. The bracket according to claim 7, wherein: The door sill extends adjacent to the battery tray and the floor of the frame.

9. The bracket according to claim 1, wherein: The carrier includes one or more substrates, one or more reinforcing materials, one or more additives, or any combination thereof.

10. The bracket according to claim 9, wherein: The one or more substrates include polymers and / or metals.

11. The bracket according to claim 10, wherein: The one or more substrates include a polymer, and the polymer includes polyamide, polyvinyl chloride polyetherimide, polycarbonate, polymethyl methacrylate, acrylonitrile-butadiene-styrene, polyetherketoneketone, polyaryletherketone, polyetheretherketone, polyphenylene sulfide, polyethylene terephthalate, polypropylene, polyethylene, or any combination thereof.

12. The bracket according to claim 10, wherein: The one or more substrates include a metal, and the metal includes aluminum, steel, brass, magnesium, zinc, titanium, or any combination thereof.

13. The bracket of claim 9, wherein: The one or more reinforcement materials include mineral reinforcements, glass reinforcements, carbon reinforcements, polymer reinforcements, elastomeric reinforcements, core-shell polymers, or any combination thereof.

14. The bracket according to claim 9, wherein: The one or more substrates used in the first and second parts are the same.

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