Fiber composite structure

Abstract

A beam includes a molded member including a green body shape of a fibrous material infused with a thermoplastic, the green body shape being formed into a first shape, and an overmolded member including an injection molding material bonded to the molded member. A method of forming a beam may include cutting a first material into a green body shape, heating the green body shape, thermoforming the green body shape into a shaped member with a first tool, and injecting a second material into an injection tool.

Description

Cross-reference to related applications

[0001] Pursuant to Section 119(e) of Title 35 of the United States Code, this patent application claims priority to U.S. Provisional Patent Application Serial No. 63 / 468,233 (Attorney General’s File No. 6474.080PRV) filed May 22, 2023, entitled “FIBER COMPOSITE STRUCTURE”, and U.S. Provisional Patent Application Serial No. 63 / 550,340 (Attorney General’s File No. 6474.080PV2) filed February 6, 2024, entitled “FIBER COMPOSITE STRUCTURE”, both of which are incorporated herein by reference in their entirety. Technical Field

[0002] This application relates to fiber composite structures for forming beams. Specifically, this application relates to molded fibers and thermoplastic composite materials combined with injection molding for forming automotive crossbeams. Background Technology

[0003] In the case of beams, what is needed are lightweight and strong beams that are easy to manufacture. Traditional beams rely on steel structures, which can be heavy and require additional processing to shape the geometry. Some solutions exist, but they cannot produce a manufacturable lightweight structure with all the required additional features. Summary of the Invention

[0004] The apparatus, systems, and methods disclosed herein have several features, none of which are solely responsible for their desired properties. Without limiting the scope expressed by the appended claims, their more prominent features will now be briefly discussed. After considering this discussion, and particularly after reading the section entitled "Detailed Description," it will be understood how the features of one or more embodiments of the system and method provide several advantages over conventional systems and methods.

[0005] In some respects, the technology described herein relates to a process for manufacturing a beam, the process comprising: heating a preform shape, the preform shape comprising a composite material comprising fibers and a first thermoplastic; thermoforming the preform shape using tools to form a thermoformed component; and overmolding the thermoformed component with a molding material comprising a second thermoplastic to form a beam, wherein overmolding the thermoformed component results in the first thermoplastic and the second thermoplastic bonding together.

[0006] In some respects, the technology described herein relates to a process that also includes cutting composite material sheets to form a preform shape.

[0007] In some respects, the technology described herein relates to a process in which the thermoforming preform shape includes: placing the preform shape into the tool; and compressing the preform shape into a thermoformed component.

[0008] In some respects, the technology described herein relates to a process in which overmolding a thermoformed component involves injecting molding material into a tool.

[0009] In some respects, the technology described herein relates to a process in which a thermoformed component has a first shape, and in which overmolding results in the molding material having a second shape different from the first shape.

[0010] In some respects, the technology described herein relates to a process in which the molding material is selected from the group consisting of polypropylene homopolymers, polypropylene copolymers, nylon homopolymers, nylon copolymers, and combinations thereof.

[0011] In some respects, the technology described herein relates to a process for manufacturing a beam, the process comprising: heating a preform shape, the preform shape comprising a composite material comprising fibers and a first thermoplastic; thermoforming the preform shape using a first tool to form a thermoformed member; and using a second tool different from the first tool to overmold the thermoformed member with a molding material comprising a second thermoplastic to form a beam, wherein overmolding the thermoformed member causes the first thermoplastic and the second thermoplastic to bond together with each other.

[0012] In some respects, the technology described herein relates to a process in which the first tool is a compression molding tool, a thermoforming tool, or an injection molding tool.

[0013] In some respects, the technology described in this article relates to a process in which the beam is a crossbeam of a vehicle.

[0014] In some respects, the technology described herein relates to a process that also includes cutting composite material sheets to form a preform shape.

[0015] In some respects, the technology described herein relates to a process that also includes: processing the thermoformed component; and inserting the thermoformed component into a second tool.

[0016] In some aspects, the technology described herein relates to a process in which processing a thermoformed component includes removing excess material from the thermoformed component or adding mounting holes or slots to the thermoformed component.

[0017] In some respects, the technology described herein relates to a process in which processing a thermoformed component includes heating the thermoformed component.

[0018] In some aspects, the technology described herein relates to a beam comprising: a thermoformed member comprising a fibrous material and a first thermoplastic material; and an overmolded member comprising a second thermoplastic material, wherein the first thermoplastic material and the second thermoplastic material are bonded to each other to connect the thermoformed member and the overmolded member.

[0019] In some respects, the technology described herein relates to a beam in which the thermoformed components are made of no steel, aluminum, or other metal materials.

[0020] In some respects, the technology described herein relates to a beam in which the encased molded component includes one or more mounting holes or one or more mounting slots.

[0021] In some respects, the technology described herein relates to a beam in which a covered molding member includes one or more covered molding strips to at least partially wrap the thermoformed member.

[0022] In some respects, the technology described herein relates to a beam, wherein the beam is a crossbeam of a vehicle.

[0023] In some respects, the technology described herein relates to beams in which the fiber material is carbon fiber, and in which the first thermoplastic material and the second thermoplastic material are nylon.

[0024] In some respects, the technology described herein relates to a beam in which a thermoformed component has a U-shaped cross-section.

[0025] In some aspects, methods of manufacturing structural elements include controlling the temperature during thermoforming and overmolding within a specific range that optimizes the combination between a first thermoplastic and a second thermoplastic, wherein the specific temperature range is between 200°C and 250°C.

[0026] In some aspects, methods of manufacturing structural elements include applying a post-treatment selected from the group consisting of heat treatment, ultraviolet (UV) radiation, and chemical treatment to enhance at least one of the structural element’s durability, environmental resistance, and mechanical strength.

[0027] In some aspects, a method for recovering or reusing materials from structural elements includes: disassembling the structural element at the end of its life cycle; and separating fibrous materials and thermoplastics for reuse or recycling.

[0028] In some aspects, the structural element includes an integrated sensor or electronic component configured to monitor at least one of structural integrity, stress level, and environmental conditions, wherein the sensor or electronic component is embedded during the overmolding process.

[0029] In some aspects, a process for manufacturing structural elements includes customizing the characteristics of the structural elements to be specifically suited for applications in environments selected from the group consisting of electric vehicles, hybrid vehicles, aerospace, and marine environments. Attached Figure Description

[0030] These and other features, aspects, and advantages of the invention are described herein with reference to the accompanying drawings of preferred embodiments, which are intended to illustrate and not limit the invention.

[0031] Figure 1 This is a perspective view based on an embodiment of a beam, using some examples.

[0032] Figure 2 These are views of blanks used to form beams, based on some examples.

[0033] Figure 3 These are perspective views of thermoformed components based on some examples.

[0034] Figure 4 This is a perspective view based on an embodiment of a beam, using some examples.

[0035] Figure 5 This is a diagram illustrating methods for forming beams based on some examples.

[0036] Figure 6 It is based on some examples Figure 5 Alternative illustrations for the method shown.

[0037] Figure 7 This is a diagram illustrating methods for forming beams based on some examples.

[0038] Figure 8 It is based on some examples Figure 7 Alternative illustrations for the method shown.

[0039] Figure 9 It is based on some examples of forming beams (such as Figure 1 A diagram illustrating the method of (the beam). Detailed Implementation

[0040] Generally speaking, one or more aspects of the present invention relate to a beam for a vehicle and a method of forming the beam. The beam structures and methods disclosed herein have broad applicability in many products and industries, including automobiles, leisure goods, shipping, boating, aerospace, and robotics. For ease of description, the beams and methods will be discussed in the context of vehicles, particularly vehicle crossbeams. However, the applications of the beams disclosed herein and the methods of forming said beams are not limited to vehicles and are applicable in many industries. Furthermore, the method can be used outside of beams to form other structural shapes. This manufacturing method can produce shapes other than beams, such as complex 3D surface geometries, with applications including, but not limited to, console structures, steering column support brackets, decorative support brackets, or local reinforcements for decorative components.

[0041] Traditional methods of vehicle beam construction rely on steel or other metals, resulting in heavy-duty beams. Further joining or mounting components to steel or other metals requires additional operations or parts. These drawbacks lead to increased costs, manufacturing time, and vehicle inefficiencies, particularly in weight-sensitive electric vehicles.

[0042] To address some drawbacks associated with conventional systems, certain embodiments described herein provide a beam for a vehicle comprising a thermoformed portion and an injection-molded portion. The resulting beam and the method of manufacturing said beam provide a low-weight beam with sufficient structural integrity.

[0043] The beam includes a thermoformed component and an overmolded portion; the thermoformed component may also be referred to as a molded component. In some embodiments, the process begins with the thermoformed component as a blank shape. In some embodiments, the blank shape is cut from a sheet of material. The material used for the thermoformed component may be a first material. The first material may be a combination of fibrous materials and thermoplastics. For example, the first material may be a fibrous material infused, impregnated, or injected with thermoplastics.

[0044] In some embodiments, the preform shape can then be heated. In some embodiments, the preform shape can be heated by a dual-sided heating device, so that the material is heated uniformly on both sides. The preform shape is then inserted into a first tool. The first tool can be a compression molding tool, a thermoforming tool, an injection molding tool, or any combination thereof. The preform shape can then be formed into a molded component. The molded component in this embodiment has a U-shaped cross-section, but it can also be other shapes. In some embodiments, the molded component remains in the first tool, and in other embodiments of the method, the molded component is removed from the first tool.

[0045] When the formed component is removed from the first tool, overmolding may occur in the second tool, or the formed component may be reinserted into the first tool. The formed component may undergo secondary processing before being inserted into the second tool and / or reinserted into the first tool used for overmolding. Secondary processing may include, for example, removing excess material using a computer numerical control (CNC) machine, adding mounting holes or slots, or any other similar operations.

[0046] While the molded component is held in a first tooling, overmolding occurs in the same tooling (e.g., the first tooling) where thermoforming takes place. Overmolding is a process of forming one material on top of another material or after another material has been formed. Overmolding may include injecting an injection-moldable material (the second material) into the first tooling. The second material is selected for injection molding so that it can bond directly to the formed component. The material used for injection molding may be the same material as the thermoplastic.

[0047] Once the formed component is overmolded with injection material, it is removed from the first or second tool. In some embodiments, the overmolded component may then undergo additional secondary processing.

[0048] Figure 1 This is a view of an embodiment of beam 100 according to this application. Beam 100 includes a thermoformed member 120 (also referred to herein as molded member 120) and an overmolded portion 140. The thermoformed member 120 is bonded to the overmolded portion 140. The molded member 120 may be made of fibrous materials and thermoplastics. The fibrous material may be carbon fiber, glass fiber, flax, aramid, Kevlar, any other fibrous material of any kind, or any combination thereof. The thermoplastic may be polypropylene homopolymer, polypropylene copolymer, nylon homopolymer, nylon copolymer, or various other thermoplastics. The overmolded portion 140 may reinforce, support, or structurally assist the molded member 120 in forming a stronger beam 100. The overmolded portion 140 may be made of any thermoplastic used for the molded member 120, such as polypropylene homopolymer, polypropylene copolymer, nylon homopolymer, or nylon copolymer.

[0049] The beam 100 may include a plurality of mounting features 102. The mounting features 102 may be formed directly in the thermoformed component 120 or in the overmolded portion 140. The mounting features 102 may be mounting holes, mounting slots, engagement features, offset features, or any other features that allow the beam 100 to be mounted to a vehicle or other components.

[0050] Figure 2This is a view of the blank shape 110. In some embodiments, the blank shape 110 is cut from a sheet of material. The blank shape 110 is formed into a forming member 120. There may be a single blank shape 110 for forming the forming member 120 or multiple blank shapes 110 for forming the forming member 120. The blank shape 110 may include a plurality of positioning holes 112 for positioning the blank shape 110 in a tool. The blank shape 110 may also include one or more cuts 104. When the blank shape 110 undergoes thermoforming in the tool, the one or more cuts 104 can help the blank shape 110 form the forming member.

[0051] Figure 3 This is a view of the molded member 120. The molded member 120 may have a U-shaped cross-section, having a top surface 122, a front surface 124, and a bottom surface 126. The molded member 120 may include various different bends 128. The bends 128 may be in the Y direction, such that the front surface 124 is not bent, but the top surface 122 and the bottom surface 126 are bent. The bends 128 may also be in the Z direction, such that the front surface 124 is bent, but the top surface 122 and the bottom surface 126 are not bent. Furthermore, the bends 128 may be a combination of X-bends and Y-bends, or may include bends in the X direction.

[0052] In some embodiments, the thickness of the molded component 120 may be between 2.2 mm and 2.4 mm, between 2 mm and 3 mm, or between 1.5 mm and 3.5 mm. In some embodiments, the molded component may have a density of 1.4 g / cm³. 3 With 1.5g / cm 3 Between 1.3 g / cm 3 With 1.6g / cm 3 Between or 1.2 g / cm 3 With 1.7g / cm 3 The material density is between 50 GPa and 60 GPa. In some embodiments, the molded component may have a material modulus between 45 GPa and 65 GPa, or between 40 GPa and 70 GPa.

[0053] Figure 4 This is a view of a beam 100 including a molded member 120 and a covered molding portion 140. The beam 100 may be a transverse member for a vehicle. The covered molding portion 140 may include a plurality of covered molding strips 142. Although the molded member 120 is directly attached to the covered molding portion 140, in some embodiments, the covered molding strips 142 may be used to completely wrap around the molded member 120.

[0054] Figure 5This is an illustration of a method 200 for forming beam 100. Method 200 begins at step 202, cutting a first material into a blank shape 110. The first material can be any combination of the aforementioned fibrous material and thermoplastic. Step 202 may include cutting a single blank shape 110 or multiple blank shapes 110. The first material can be cut using a laser, water jet, mold, or any other suitable method.

[0055] Step 204 includes heating the billet shape 110. In some embodiments, the billet shape 110 may be heated in a double-sided oven or any other type of oven. Heating makes the material more malleable, thus making it easier to form.

[0056] Step 206 includes thermoforming the blank shape(s) 110 into a molded component 120. Step 206 may include multiple sub-steps, such as preheating a first tool, placing the blank shape 110 into the first tool, applying pressure, compressing, or heating to form the blank shape 110 into the molded component 120. Once the blank shape 110 has been formed, the first tool may remain closed or open prior to step 208.

[0057] Step 208 includes injecting a second material into the first tool. The second material can be any injection-molded material, such as a polypropylene homopolymer, a polypropylene copolymer, a nylon homopolymer, or a nylon copolymer. Step 208 may include bonding the injected second material to the molded component 120. Due to the choice of material, i.e., when the thermoplastic and the second material are the same, bonding can occur naturally.

[0058] It should be understood that method 200 may include all steps 202-208 or a portion thereof. Furthermore, method 200 may include additional steps.

[0059] Figure 6 This is an alternative illustration of a part of method 200. The method includes step 206, thermoforming a preform shape 110 into a molded component 120. In this embodiment, step 206 includes a sub-step 206.1 for placing the preform shape 110 into a first tool, and a sub-step 206.2 for compressing the preform shape 110 into the molded component 120. Step 208 includes injecting a second material into the first tool, i.e., overmolding the molded component 120.

[0060] Figure 7 This is an illustration of a method 300 for forming beam 100. Method 300 begins at step 302, cutting a first material into a blank shape 110. The first material can be any combination of the aforementioned fibrous material and thermoplastic. Step 302 may include cutting a single blank shape 110 or multiple blank shapes 110. Step 302 may be the same as or similar to step 202.

[0061] Step 304 includes heating the billet shape 110. In some embodiments, the billet shape may be heated in a double-sided oven. Heating makes the material more ductile, thus making it easier to form. Step 304 may be the same as or similar to step 204.

[0062] Step 306 includes thermoforming the preform shape(s) 110 into a molded component 120. Step 306 may include multiple sub-steps, such as preheating a first tool, placing the preform shape 110 into the first tool, applying pressure, compressing, or heating to form the preform shape 110 into the molded component 120. Once the preform shape 110 has been formed, the first tool is opened to release the molded component 120. Step 306 may be the same as or similar to step 206. In some embodiments, the first tool may be a compression molding tool, a thermoforming tool, an injection molding tool, or any combination thereof.

[0063] Step 308 includes performing secondary processing on the molded component 120. Secondary processing may include removing excess material from the molded component 120. Secondary processing may also include adding holes, slots, or other features to the molded component 120. In some embodiments, step 308 may be optional with respect to method 300.

[0064] Step 310 includes placing or inserting the molded component 120 into a second tool. The second tool may be an injection molding tool. The second tool may be different from the first tool used in step 306.

[0065] Step 312 includes injecting a second material into the second tool. The second material may be a thermoplastic resin and / or any injection-moldable material, such as a polypropylene homopolymer, a polypropylene copolymer, a nylon homopolymer, a nylon copolymer, or a combination thereof. Step 312 may include bonding the injected second material to the molded component 120. Due to the choice of material, i.e., when the thermoplastic and the second material are the same, bonding can occur naturally.

[0066] It should be understood that method 300 may include all steps 302-312 or a portion thereof. Furthermore, method 300 may include additional steps.

[0067] Figure 8This is an alternative illustration of a part of method 300. The method includes step 306, thermoforming a preform shape 110 into a molded member 120. In this embodiment, step 306 includes a sub-step 306.1 of placing the preform shape 110 into a first tool, and a sub-step 306.2 of compressing the preform shape 110 into the molded member 120. Step 310 includes placing the molded member 120 into a second tool. Step 312 includes closing the second tool and injecting a second material into the second tool. The second material used to form the overmolded portion 140 may be bonded to the first material of the molded member 120. For example, the first material may include a thermoplastic composition. The second material may include a thermoplastic resin or any other material, including a thermoplastic composition. Because the first and second materials share a common thermoplastic composition, the bonding between the first and second materials may occur spontaneously or naturally after the second material is injected into the second tool. Once the injection molding in step 312 is completed, the beam 100 is removed from the second tool.

[0068] Figure 9 This is an illustration of a method 400 for forming beam 100. Method 400 may be similar to method 200 or method 300 and may share any of the previously described steps. Method 400 begins at step 402, cutting a first material into a blank shape 110. The first material may be any combination of the aforementioned fibrous material and thermoplastic. Step 402 may include cutting a single blank shape 110 or multiple blank shapes 110. Step 402 may be the same as or similar to steps 202 or 302.

[0069] Step 404 includes heating the billet shape 110. In some embodiments, the billet shape may be heated in a double-sided oven or any other type of furnace. Heating makes the material more ductile, thus making it easier to form. Step 404 may be the same as or similar to steps 204 or 304.

[0070] Step 406 includes thermoforming the blank shape(s) 110 into a molded component 120. Step 406 may include several sub-steps, such as preheating a first tool, placing the blank shape 110 into the first tool, applying pressure, compression, or heating to form the blank shape 110 into the molded component 120. Once the blank shape 110 has been formed, the first tool is opened to release the molded component 120. Step 406 may be the same as or similar to steps 206 or 306.

[0071] Step 408 includes performing secondary processing on the molded component 120. Secondary processing may include removing excess material from the molded component 120. Secondary processing may also include adding holes, slots, or other features to the molded component 120.

[0072] Step 410 includes heating the molded component 120. In some embodiments, the molded component 120 may be heated in a double-sided oven. The heat can promote strong bonding and / or adhesion between the molded component 120 and the material to be injected to bond with the molded component 120. Additionally and / or alternatively, step 410 may include an adhesion-enhancing process such as plasma or flame treatment to further enhance the bonding.

[0073] Step 412 includes placing or inserting the molded component 120 into a second tool. The second tool may be an injection molding tool.

[0074] Step 414 includes injecting a second material into the second tool. The second material may be a thermoplastic resin and / or any injection-moldable material, such as a polypropylene homopolymer, a polypropylene copolymer, a nylon homopolymer, a nylon copolymer, or any combination thereof. Step 414 may include bonding the injected second material to the molded member 120. Due to the choice of materials, i.e., when the thermoplastic and the second material are the same, bonding may occur spontaneously. For example, the first material may include a thermoplastic composition. The second material may include a thermoplastic resin or any other material comprising a thermoplastic composition. Because the first and second materials share a common thermoplastic composition, bonding between the first and second materials may occur spontaneously or spontaneously after the second material is injected into the second tool.

[0075] It should be understood that method 400 may include all steps 402-414 or a portion thereof. Furthermore, method 400 may include additional steps.

[0076] In some embodiments, precise temperature control is provided to obtain optimal material properties and bond strength. The thermoforming and overmolding processes are performed within a specific temperature range of 200°C to 250°C, which has been found to optimize or at least enhance the bond between the first and second thermoplastics. This temperature range aims to ensure that the thermoplastics have sufficient ductility to form a strong bond without degrading the fibrous material.

[0077] To further enhance the properties of structural components, various post-treatment processes can be applied in some examples. These processes include heat treatment to relieve internal stress, UV radiation to improve environmental resistance, and chemical treatments to enhance surface properties. Each process is tailored to the specific requirements of the application to ensure that the final product meets the highest standards of durability and performance.

[0078] In some examples, a comprehensive life cycle assessment is used to evaluate the environmental impact of the manufacturing process and the final product. These assessments evaluate the carbon footprint, resource use, and recyclability of the materials used. Fiber composite structures are designed to be environmentally friendly, with a focus on reducing waste and enabling materials to be recycled or reused at the end of the product's life cycle.

[0079] In some examples, structural elements are integrated with sensors or electronic components to provide real-time monitoring capabilities. These components are embedded during the overmolding process and are able to monitor structural integrity, detect stress levels, and assess environmental conditions. This integration allows for proactive maintenance and ensures the long-term reliability of structural elements across a variety of applications.

[0080] In some examples, the characteristics of structural elements are customized to meet the specific needs of various applications. For instance, the flexibility, rigidity, or thermal insulation properties can be modified to make the structural elements suitable for electric vehicles where weight and battery efficiency may be important, or for aerospace applications that may require a high strength-to-weight ratio. Example

[0081] Therefore, some implementation schemes may include one or more of the following examples. Example 1. A process for manufacturing a structural element, the process comprising: Heating a preform shape, the preform shape comprising a composite material comprising fibers and a first thermoplastic; Using tools, the preform is thermoformed to form a thermoformed component; and Using the tool, the thermoformed member is overmolded with a molding material comprising a second thermoplastic to form the structural element, wherein overmolding the thermoformed member causes the first thermoplastic and the second thermoplastic to bond together. Example 2. The process described in Example 1 further includes cutting the composite material sheet to form the blank shape. Example 3. According to the process described in Example 1 or 2, the shape of the preform in the thermoforming includes: Insert the blank shape into the tool; and The blank shape is compressed into the thermoformed component. Example 4. The process according to any one of Examples 1 to 3, wherein overmolding the thermoformed component includes injecting the molding material into the tool. Example 5. The process according to any one of Examples 1 to 4, wherein the thermoformed component has a first shape, and wherein overmolding results in the molding material having a second shape different from the first shape. Example 6. The process according to any one of Examples 1 to 5, wherein the molding material is selected from the group consisting of: polypropylene homopolymers, polypropylene copolymers, nylon homopolymers, nylon copolymers, and combinations thereof. Example 7. A process for manufacturing a structural element, the process comprising: Heating a preform shape, the preform shape comprising a composite material comprising fibers and a first thermoplastic; Using a first tool, the preform is thermoformed to form a thermoformed component; and Using a second tool different from the first tool, the thermoformed member is overmolded with a molding material comprising a second thermoplastic to form the structural element, wherein overmolding the thermoformed member causes the first thermoplastic and the second thermoplastic to bond together. Example 8. The process according to Example 7, wherein the first tool is a compression molding tool, a thermoforming tool, or an injection molding tool. Example 9. The process according to Example 7 or 8, wherein the structural element is a vehicle beam. Example 10. The process according to any one of Examples 7 to 9, further comprising cutting the composite material sheet to form the blank shape. Example 11. The process according to any one of Examples 7 to 10 further includes: Processing the thermoformed component; and The thermoformed component is inserted into the second tool. Example 12. The process according to Example 11, wherein processing the thermoformed component includes removing excess material from the thermoformed component or adding mounting holes or slots to the thermoformed component. Example 13. The process according to Example 11 or 12, wherein processing the thermoformed component includes heating the thermoformed component. Example 14. The process according to any one of Examples 7 to 13, wherein overmolding the thermoformed component includes injecting the molding material into the second tool. Example 15. A beam comprising: Thermoformed components, comprising fibrous materials and a first thermoplastic material; and An overmolded component is attached to the thermoformed component, the overmolded component comprising a second thermoplastic material. The first thermoplastic material and the second thermoplastic material are bonded to each other to connect the thermoformed component and the overmolded component. Example 16. The beam according to Example 15, wherein the thermoformed component is not made of steel, aluminum or other metal materials. Example 17. A beam according to Example 15 or 16, wherein the overmolded member includes one or more mounting holes or one or more mounting slots. Example 18. A beam according to any one of Examples 15 to 17, wherein the overmolded member comprises one or more overmolded strips to at least partially enclose the thermoformed member. Example 19. A beam according to any one of Examples 15 to 18, wherein the fiber material comprises carbon, aramid, or natural fiber, and wherein the first thermoplastic material and the second thermoplastic material comprise nylon or thermoplastic materials or blends thereof. Example 20. A beam according to any one of Examples 15 to 19, wherein the thermoformed member has a U-shaped, C-shaped or I-shaped cross-sectional shape. Example 21. A beam comprising: Molded components, including a preform shape of fibrous material infused with thermoplastic plastic, said preform shape being formed into a first shape; and Overmolded components include injection molding material bonded to the molded components. Example 22. A beam according to Example 21, wherein the beam is a vehicle crossbeam. Example 23. A beam according to Example 21 or 22, wherein the first shape is a U-shaped beam. Example 24. A beam according to any one of Examples 21 to 23, wherein the fiber material is carbon fiber and the thermoplastic is nylon. Example 25. A beam according to any one of Examples 21 to 24, wherein the injection molding material is nylon. Example 26. A beam according to any one of Examples 21 to 25, wherein the injection molding material is the same material as the thermoplastic, and the injection molding material is directly bonded to the thermoplastic during the injection molding process. Example 27. A method for forming a beam, the method comprising: The first material is cut into a blank shape; Heating the blank to shape; The blank shape is thermoformed into a molded component using a first tool; The molded component is inserted into the injection molding tool; Injecting the second material into the injection tool; and The first material is directly bonded to the second material. Example 28. The method according to Example 27, wherein injecting the second material into the injection tool further includes directly bonding the first material to the second material. Example 29. A method for forming a beam, the method comprising: The first material is cut into a blank shape; Heating the blank to shape; The blank shape is thermoformed into a molded component using a first tool; The molding component is formed by covering and molding it with a second material within the first tool; and The first material is directly bonded to the second material. Example 30. The method according to Example 29, wherein overmolding the molded component with the second material further includes directly bonding the second material to the molded component.

[0082] Example 31. A structural beam comprising an overmolded member injection-molded into a thermoformed member, the thermoformed member comprising a fibrous material and a thermoplastic material, wherein the injection-molded overmolded member comprises the thermoplastic material.

[0083] The foregoing disclosure is not intended to limit this disclosure to the precise form disclosed or to any particular field of application. Therefore, various alternative embodiments and / or modifications of this disclosure are possible, whether expressly described or implied herein. Since embodiments of this disclosure have been so described, those skilled in the art will recognize that changes in form and detail may be made without departing from the scope of this disclosure. Therefore, this disclosure is defined only by the claims.

[0084] In the foregoing description, this disclosure has been described with reference to specific embodiments. However, as those skilled in the art will appreciate, the various embodiments disclosed herein can be modified or otherwise implemented in various other ways without departing from the spirit and scope of the invention. Therefore, this specification is intended to be illustrative and to teach those skilled in the art how to manufacture and use the various embodiments of the disclosed materials, elements, and crossbeams. It should be understood that the form of the disclosure shown and presented herein should be considered representative of the embodiments. Equivalent elements, materials, processes, or steps may be substituted for those representatively shown and described herein. Furthermore, certain features of this disclosure may be utilized independently of the use of other features, all of which will be apparent to those skilled in the art who have benefited from this specification. Expressions such as “comprising,” “including,” “incorporated,” “consisting of,” “having,” “is,” etc., used to describe and claim this disclosure are intended to be interpreted in a non-exclusive manner, allowing for the presence of items, components, or elements not explicitly described. References to the singular are also interpreted to refer to the plural.

[0085] Furthermore, the various embodiments disclosed herein should be understood in an illustrative and explanatory sense and should in no way be construed as limiting the invention. All connecting references (e.g., attachment, affixation, coupling, connection, etc.) are used only to assist the reader in understanding this disclosure and may not impose limitations, particularly regarding the location, orientation, or use of the systems and / or methods disclosed herein. Therefore, connecting references, if any, will be interpreted broadly. Moreover, such connecting references do not necessarily imply that two elements are directly connected to each other. Additionally, all numerical terms such as, but not limited to, “first,” “second,” “third,” “primary,” “minor,” “main,” or any other common and / or numerical terms should also be considered merely as identifiers to assist the reader in understanding the various elements, embodiments, variations, and / or modifications of this disclosure and may not impose any limitations, particularly regarding the order or preference of any element, embodiment, variation, and / or modification relative to or exceeding another element, embodiment, variation, and / or modification.

[0086] It should also be understood that one or more elements depicted in the accompanying drawings may also be implemented in a more discrete or integrated manner, or even removed or rendered inoperable in some cases, as may be useful for a particular application.

Claims

1. A process for manufacturing a structural element, the process comprising: Heating a preform shape, the preform shape comprising a composite material comprising fibers and a first thermoplastic; The blank is thermoformed into a shape using tools to form a thermoformed component; as well as By using the tool, the thermoformed member is overmolded with a molding material comprising a second thermoplastic to form the structural element, wherein overmolding the thermoformed member causes the first thermoplastic and the second thermoplastic to bond together.

2. The process according to claim 1 further includes cutting the composite material plate to form the blank shape.

3. The process according to claim 1, wherein the shape of the preform in thermoforming includes: Insert the blank shape into the tool; as well as The blank shape is compressed into the thermoformed component.

4. The process of claim 1, wherein overmolding the thermoformed component comprises injecting the molding material into the tool.

5. The process of claim 1, wherein the thermoformed component has a first shape, and wherein overmolding results in the molding material having a second shape different from the first shape.

6. The process according to claim 1, wherein the molding material is selected from the group consisting of: polypropylene homopolymers, polypropylene copolymers, nylon homopolymers, nylon copolymers, and combinations thereof.

7. A process for manufacturing a structural element, the process comprising: Heating a preform shape, the preform shape comprising a composite material comprising fibers and a first thermoplastic; The blank is thermoformed using a first tool to form a thermoformed component; as well as The thermoformed component is molded by overmolding with a molding material comprising a second thermoplastic to form the structural element using a second tool different from the first tool, wherein overmolding the thermoformed component bonds the first thermoplastic and the second thermoplastic to each other.

8. The process according to claim 7, wherein the first tool is a compression molding tool, a thermoforming tool, or an injection molding tool.

9. The process according to claim 7, wherein the structural element is a vehicle crossbeam.

10. The process of claim 7, further comprising cutting the composite material plate to form the blank shape.

11. The process according to claim 7, further comprising: Process the thermoformed component; as well as The thermoformed component is inserted into the second tool.

12. The process of claim 11, wherein processing the thermoformed component includes removing excess material from the thermoformed component or adding mounting holes or grooves to the thermoformed component.

13. The process of claim 12, wherein processing the thermoformed component includes heating the thermoformed component.

14. The process of claim 12, wherein overmolding the thermoformed component comprises injecting the molding material into the second tool.

15. A beam comprising: Thermoformed components, comprising fibrous materials and a first thermoplastic material; as well as An overmolded component is attached to the thermoformed component, the overmolded component comprising a second thermoplastic material. The first thermoplastic material and the second thermoplastic material are bonded to each other to connect the thermoformed component and the overmolded component.

16. The beam of claim 15, wherein the thermoformed component is not made of steel, aluminum or other metal materials.

17. The beam of claim 15, wherein the overmolded member comprises one or more mounting holes or one or more mounting slots.

18. The beam of claim 15, wherein the overmolded member comprises one or more overmolded strips to at least partially enclose the thermoformed member.

19. The beam of claim 15, wherein the fiber material comprises carbon, aramid, or natural fiber, and wherein the first thermoplastic material and the second thermoplastic material comprise nylon or thermoplastic materials or blends thereof.

20. The beam according to claim 15, wherein the thermoformed component has a U-shaped, C-shaped, or I-shaped cross-sectional shape.

21. A beam comprising: A molded component, comprising a preform shape of fibrous material infused with thermoplastic plastic, the preform shape being formed into a first shape; as well as Overmolded components include injection molding material bonded to the molded components.

22. The beam of claim 21, wherein the beam is a vehicle crossbeam.

23. The beam according to claim 21, wherein the first shape is a U-shaped beam.

24. The beam according to claim 21, wherein the fiber material is carbon fiber and the thermoplastic is nylon.

25. The beam of claim 21, wherein the injection molding material is nylon.

26. The beam of claim 21, wherein the injection molding material is the same material as the thermoplastic, and the injection molding material is directly bonded to the thermoplastic during the injection molding process.

27. A method of forming a beam, the method comprising: The first material is cut into a blank shape; Heating the blank to shape; The blank shape is thermoformed into a molded component using a first tool; Insert the molded component into the injection molding tool; The second material is injected into the injection tool; as well as The first material is directly bonded to the second material.

28. The method of claim 27, wherein injecting the second material into the injection tool further comprises directly bonding the first material to the second material.

29. A method of forming a beam, the method comprising: The first material is cut into a blank shape; Heating the blank to shape; The blank shape is thermoformed into a molded component using a first tool; The shaped component is molded by covering it with a second material within the first tool; as well as The first material is directly bonded to the second material.

30. The method of claim 29, wherein overmolding the molded member with the second material further comprises directly bonding the second material to the molded member.

31. A structural beam comprising an overmolded member injection-molded into a thermoformed member, the thermoformed member comprising a fibrous material and a thermoplastic material, wherein the injection-molded overmolded member comprises the thermoplastic material.

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