Injection-molded reinforcing member

Abstract

The present invention relates to a system comprising a structure having a cavity and a reinforcing member, the cavity having a longitudinal extension, the reinforcing member having a longitudinal extension and a transverse extension, a plurality of longitudinal ribs disposed in a plane along the longitudinal and transverse directions, and a plurality of transverse ribs extending in the transverse direction, wherein the longitudinal ribs and transverse ribs form a plurality of channels extending in the transverse direction, wherein a frame is provided in each channel.

Description

Technical Field

[0001] This invention relates to a system comprising a structure having a cavity and a reinforcing member, the cavity having a longitudinal extension, and the reinforcing member having:

[0002] -Longitudinal extension and lateral extension

[0003] - Multiple longitudinal ribs, all arranged in a plane along the longitudinal and transverse directions;

[0004] - Multiple transverse ribs, all extending in the transverse direction.

[0005] The longitudinal and transverse ribs form multiple channels that extend in the transverse direction.

[0006] A frame is provided in each channel. Background Technology

[0007] Such systems are known, for example, in US Patent 10,926,804; however, their damping characteristics are limited.

[0008] Therefore, this system always needs to be improved. Summary of the Invention

[0009] The object of the present invention is achieved by a system comprising a structure having a cavity and a reinforcing member, the cavity having a longitudinal extension, and the reinforcing member having:

[0010] -Longitudinal extension and lateral extension

[0011] - Multiple longitudinal ribs, all arranged in the plane along both the longitudinal and transverse directions.

[0012] - Multiple transverse ribs, all extending in the transverse direction.

[0013] The longitudinal ribs and transverse ribs form multiple channels, which extend in the transverse direction.

[0014] This includes providing a frame in each channel; and

[0015] The wall thickness of the longitudinal ribs is not constant in its transverse direction.

[0016] The disclosures made in this subject also apply to other subjects, and vice versa. Subjects disclosed in this subject can be incorporated into other subjects, and vice versa.

[0017] This invention relates to a system comprising a structure having a cavity. The structure is preferably part of a vehicle, such as a rocker arm, and more preferably a rocker arm adjacent to a battery housing of the vehicle. The cavity of the structure includes a longitudinal axis. This longitudinal axis is preferably parallel to the longitudinal direction of the vehicle.

[0018] The system also includes a reinforcing member disposed within the cavity of the structure. The reinforcing member has a longitudinal extension, preferably its longest extension. The longitudinal extension is preferably parallel to the longitudinal axis of the structure. The reinforcing member also includes a transverse extension disposed at an angle relative to the longitudinal extension, preferably at a 90° angle. The transverse extension of the reinforcing member is substantially the same as the transverse extension of the cavity of the structure, preferably slightly smaller, because preferably, a gap is provided between the reinforcing member and the inner wall of the cavity.

[0019] According to the invention, the reinforcing member comprises a plurality of longitudinal ribs, each longitudinal rib being disposed in a plane along both the longitudinal and transverse directions. These ribs are preferably parallel to each other. The ribs are preferably stacked vertically.

[0020] Furthermore, the reinforcing member includes multiple transverse ribs, each extending in the transverse direction of the reinforcing member. Each rib is preferably vertically positioned. The transverse ribs are positioned at an angle relative to the longitudinal extension. The angle can be 90° or a different angle between 1° and 179°.

[0021] Longitudinal ribs, together with transverse ribs, form multiple channels that extend in the transverse direction. For example, two longitudinal ribs and two transverse ribs, or one longitudinal rib and two transverse ribs, can form a channel. The length of the channel is preferably formed by the horizontal extension of the channel and the formation of a multi-row, multi-column channel array. The distance between two opposite transverse ends of the reinforcing member defines the length of the channel.

[0022] A frame is provided in each channel, which locally reduces the cross-section of that channel. The frame preferably extends only a small portion of the channel's length. The frame is preferably positioned in the middle relative to its length. The frame may be positioned in the plane of symmetry of the reinforcing member.

[0023] According to the invention, the wall thickness of the longitudinal rib is not constant in its transverse direction. Preferably, the wall thickness decreases towards the transverse end of the reinforcing member, more preferably at the two opposite ends, and more preferably from the middle towards the transverse end. The angle resulting from the wall thickness variation is preferably greater than the draft angle required for injection molding. Preferably, this angle is greater than 1°, more preferably 2°, more preferably 3°, and even more preferably 4° or greater.

[0024] It has been found that the damping performance has been improved due to the change in wall thickness.

[0025] Preferably, the wall thickness of the transverse ribs is not constant in the transverse direction. Preferably, the wall thickness decreases towards the transverse end of the reinforcing member, preferably at the two opposite ends, and preferably from the middle towards the transverse end. The angle resulting from the wall thickness variation is preferably greater than the draft angle required for injection molding. Preferably, this angle is greater than 1°, preferably 2°, more preferably 3°, and even more preferably 4° or greater.

[0026] It has been found that the damping performance is improved due to the change in wall thickness.

[0027] According to another or preferred embodiment of the invention, the reinforcing member is made of a material containing a polymeric material, preferably polyamide (PA), more preferably PA6.

[0028] The disclosures made in this subject also apply to other subjects, and vice versa. Subjects disclosed in this subject can be incorporated into other subjects, and vice versa.

[0029] According to this subject matter of the invention, the reinforcing member comprises a polymeric material. Preferably, the reinforcing member is injection molded.

[0030] Preferably, the polymeric material includes fillers, more preferably fillers for improving toughness and / or ductility. Fillers that improve strength, such as fibers, are not desired and should not be added.

[0031] Preferably, the polymeric material comprises an elastomeric material, which preferably accounts for 20% by weight. The material exhibiting a rubbery texture is preferably a desired elastomeric material. Such an elastomeric material can be added as a filler.

[0032] Preferably, the polymeric material contains T G Impact modifier with a temperature range of <45℃. This impact modifier can be added as a filler.

[0033] Preferably, the reinforcing member is made of a polymeric material having at least one of the following properties:

[0034] - Tensile modulus > 1500 MPa

[0035] - Elongation at break > 50%

[0036] -Charpy notched impact strength is 80 to 100 kJ / m 2 .

[0037] According to a preferred embodiment of the invention, the reinforcement is attached to the structure by an adhesive device, preferably one or more patches. The adhesive device preferably reduces, for example, noise due to vibration and / or reduces fatigue of the reinforcement. The adhesive device preferably does not provide stability.

[0038] Preferably, there is a gap between the structure and the reinforcement.

[0039] In a preferred embodiment, the cross-section is rectangular, square, or triangular.

[0040] The system of the present invention is applicable to vehicles, especially motorized vehicles, preferably electrically driven motorized vehicles.

[0041] Another subject of the invention is therefore a vehicle that includes the system of the invention.

[0042] The disclosures made in this subject also apply to other subjects, and vice versa. Subjects disclosed in this subject can be incorporated into other subjects, and vice versa.

[0043] This system is specifically designed to protect the battery casing of electrically driven vehicles, preferably from side impacts.

[0044] Preferably, the system has a reinforced rocker arm. Attached Figure Description

[0045] The invention will now be explained with reference to the accompanying drawings. These explanations are merely exemplary and do not limit the scope of protection.

[0046] Figures 1 to 3 An embodiment of the reinforcing member 1 is shown.

[0047] Figure 4 and Figure 5 The load analysis of the reinforcing member 1 is shown.

[0048] Figure 6 and Figure 7 Details of reinforcing member 1 are shown. Detailed Implementation

[0049] Figures 1 to 3 An embodiment of the reinforcing member 1 is shown. The reinforcing member is placed into a cavity (not shown) of the structural element. The reinforcing member 1 has a longitudinal extension LD, which preferably coincides with the longitudinal extension of the structural element (e.g., a rocker arm on the longitudinal side of a vehicle). The reinforcing member also has a lateral extension TD, which is an extension perpendicular to the longitudinal extension. The lateral extension is, for example, the width of the reinforcing member 1. Furthermore, the reinforcing member 1 has a second lateral extension, which is, for example, the height of the reinforcing member 1. The lateral extension of the reinforcing member 1 is preferably slightly smaller than the cross-sectional dimension of the structural element, thereby creating a gap between the structural element and the reinforcing member 1.

[0050] According to the invention, the reinforcing member 1 has at least one (here, four) longitudinal ribs 2, each longitudinal rib 2 having extensions in both the longitudinal and transverse directions. In the vehicle, the longitudinal ribs 2 are preferably arranged in a horizontal plane. In the transverse direction, preferably, one transverse end face of the longitudinal rib faces the side of the vehicle, and the opposite transverse end faces the interior of the vehicle, preferably the battery housing. The longitudinal ribs 2 are stacked on top of each other, preferably stacked on top of each other in the horizontal direction. The distance between two adjacent longitudinal ribs 2 is constant in this example. However, those skilled in the art will understand that this distance can vary.

[0051] The reinforcing member 1 also includes a plurality of transverse ribs 3, which are arranged at a 90° angle relative to the longitudinal extension. Each transverse rib 3 has a transverse extension TD, which is preferably equal to or slightly smaller than the extension of the structural element in that direction. In this case, the transverse ribs are arranged parallel and equidistantly, but those skilled in the art will understand that this can be different. The transverse ribs 3 may have different angles relative to the longitudinal extension, and / or adjacent transverse ribs may have different distances.

[0052] In this configuration, two adjacent longitudinal ribs 2 and two adjacent transverse ribs form a channel 4, which preferably extends along the entire transverse extension of the reinforcing member 1. The channel 4 has a square cross-section, but it can also be rectangular or triangular. The channel can be used to guide coating material applied to the structural element and / or to guide cooling medium after injection molding. The size and / or shape of the channel 4 is optimized considering the flow of at least one medium and the required stability of the reinforcing member.

[0053] At one distal end, the reinforcing member 1 may be provided with a cover 6.

[0054] The reinforcing member 1 is made of a polymeric material, preferably polyamide (PA), more preferably PA6, and more preferably includes compounds for improving the toughness and / or ductility of the polymeric material. It is preferable to avoid the presence of fiber-like fillers.

[0055] Figure 2 This is a cross-sectional view along the cutting line AA. It can be seen that the thickness of the transverse extension of the longitudinal rib is not constant, but decreases continuously towards the end in the transverse direction from the maximum thickness (in this case, the middle). The resulting slope of the rib's side surface is greater than the slope required for forming the reinforcing member 1 from the mold.

[0056] from Figure 2 and Figure 3 As can be seen, a frame 5 is provided in each channel, extending along the entire inner circumference of the channel 4 and locally reducing the cross-sectional dimensions of the channel. In this case, the frame 5 is positioned in the central plane of the reinforcing member 1.

[0057] Figure 4 and Figure 5 The reinforcement member 1, indicated by large arrow 9, is shown during the impact. Initially, the load within reinforcement member 1 increases sharply until the transverse ends of the longitudinal ribs begin to fold (see...). Figure 5 During the folding process, the load still increases, but the slope decreases significantly.

[0058] Figure 6 Details of the reinforcing member 1 are shown. An adhesive device 7 is provided to secure the reinforcing member 1 to the structure, not to provide additional reinforcement but to reduce noise and / or fatigue of the reinforcing member 1. The securing device 7 may be configured to further attach the reinforcing member 1 to structural elements.

[0059] Figure 7 Details of the longitudinal rib 2 are shown. The angle α produced by the change in thickness is greater than the angle required to remove the reinforcing member 1 from the mold.

[0060] Figure label:

[0061] 1. Reinforcing Components

[0062] 2 longitudinal ribs

[0063] 3 transverse ribs

[0064] 4 channels

[0065] 5-framework

[0066] 6 lids

[0067] 7. Adhesive device, CBS patch

[0068] 8 Fixing devices

[0069] 9 loads

[0070] α angle

[0071] LD longitudinal extension

[0072] TD lateral extension

Claims

1. A system comprising a structure having a cavity and a reinforcing member (1), the cavity having a longitudinal extension, the reinforcing member having: - Longitudinal extension (LD) and transverse extension (TD), - Multiple longitudinal ribs (2), all of which are arranged in the plane along the longitudinal and transverse directions. - Multiple transverse ribs (3), all extending along the transverse direction. The longitudinal ribs (2) and the transverse ribs (3) form a plurality of channels that extend along the transverse direction. in, Provide a frame (5) in each channel. The feature is that the wall thickness of the longitudinal rib is not constant in its transverse direction (TD).

2. The system according to claim 1, characterized in that, The wall thickness of the transverse rib (3) is not constant in the transverse direction.

3. The system according to any one of the preceding claims, characterized in that, The wall thickness increases toward the center of the reinforcing member (1).

4. The system according to any one of the preceding claims or the preamble of claim 1, characterized in that, The reinforcing member is made of a material comprising a polymer, preferably PA, more preferably PA6.

5. The system according to claim 4, characterized in that, It includes fillers to improve toughness and / or ductility.

6. The system according to claim 4 or 5, characterized in that, The material includes an elastomer material, which preferably comprises 20% by weight.

7. The system according to claims 4 to 6, characterized in that, The material includes T G Impact modifier for temperatures below 45℃.

8. The system according to claims 4 to 7, characterized in that, The reinforcing member is made of a polymeric material having at least one of the following properties: - Tensile modulus > 1500 MPa - Elongation at break > 50% - Charpy notched impact strength is 80 to 100 kJ / m 2 .

9. The system according to any one of the preceding claims, characterized in that, The reinforcing member is attached to the structure using an adhesive device, preferably one or more patches.

10. The system according to any one of the preceding claims, characterized in that, There is a gap between the structure and the reinforcing member.

11. The system according to any one of the preceding claims, characterized in that, The cross-section is rectangular, square, or triangular.

12. A vehicle comprising the system according to any one of the preceding claims.

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