Fiber composite structure

Abstract

A beam comprising a molded member having a blank shape of fibrous material into which a thermoplastic material formed into a first shape has been injected, and an overmolded member having an injection-molded material bonded to the molded member. A method for forming a beam, which may include cutting a first material into a blank shape, heating the blank shape, thermoforming the blank shape into a molded member with a first tool, and injecting a second material into an injection molding tool.

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This patent application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 63 / 468,233, titled "FIBER COMPOSITE STRUCTURE," filed on May 22, 2023, by Shenk et al. (Attorney Docket No. 6474.080PRV), and U.S. Provisional Patent Application No. 63 / 550,340, titled "FIBER COMPOSITE STRUCTURE," filed on February 6, 2024, by Shenk et al. (Attorney Docket No. 6474.080PV2), the entire disclosures of both provisional applications being incorporated herein by reference.

[0002] This application relates to fiber composite structures used to form beams. Specifically, this application relates to molded fibers and thermoplastic composites combined with injection molding used to form curved beams.

Background Art

[0003] In the context of beams, lightweight and strong beams that can be easily manufactured are needed. Conventional beams rely on steel structures, which can be heavy and may require additional secondary operations to form the shape. There are several solutions, but none can produce a manufacturable lightweight structure with all the required additional features.

Summary of the Invention

Problems to be Solved by the Invention

[0004] The devices, systems, and methods disclosed herein possess several functions, and none of them alone represent their desired attributes. Their more prominent functions are briefly discussed here without limiting the scope expressed by subsequent claims. After considering this discussion, and in particular after reading the section titled “Modes for Carrying Out the Invention,” you will understand how the features of one or more embodiments of the systems and methods offer several advantages over conventional systems and methods. [Means for solving the problem]

[0005] In some embodiments, the techniques described herein relate to a process for manufacturing a beam, the process comprising: heating a blank shape (blank shape) wherein the blank shape comprises a composite material comprising fibers and a first thermoplastic material; thermoforming the blank shape using a tool to form a thermoformable member; and overmolding the thermoformable member with a molding material comprising a second thermoplastic material to form a beam, wherein the overmolding of the thermoformable member causes the first thermoplastic material and the second thermoplastic material to bond to each other.

[0006] In some embodiments, the techniques described herein relate to a process that further includes cutting a composite material sheet to form a blank shape.

[0007] In some embodiments, the techniques described herein relate to a process in which thermoforming a blank shape body includes placing the blank shape body into a tool and compressing the blank shape body into a thermoforming member.

[0008] In some embodiments, the techniques described herein relate to a process in which overmolding a thermoformable member includes injecting a molding material into a tool.

[0009] In some embodiments, the techniques described herein relate to a process in which a thermoformed member has a first shape, and by overmolding, the molded material has a second shape different from the first shape.

[0010] In some embodiments, the techniques described herein relate 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 embodiments, the techniques described herein relate to a process for manufacturing a beam, the process comprising: heating a blank shape body, wherein the blank shape body comprises a composite material comprising fibers and a first thermoplastic material; thermoforming the blank shape body to form a thermoformable member using a first tool; and overmolding the thermoformable member with a molding material comprising a second thermoplastic material to form a beam using a second tool different from the first tool, wherein the first thermoplastic material and the second thermoplastic material are bonded to each other by overmolding the thermoformable member.

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

[0013] In some embodiments, the techniques described herein relate to a process in which the beam is a cross-vehicle beam.

[0014] In some embodiments, the techniques described herein relate to a process that further includes cutting a composite material sheet to form a blank shape.

[0015] In some embodiments, the techniques described herein relate to a process that further includes processing a thermoformable member and inserting the thermoformable member into a second tool.

[0016] In some embodiments, the techniques described herein relate to a process in which processing a thermoformed member includes removing excess material from the thermoformed member or adding mounting holes or mounting slots to the thermoformed member.

[0017] In some embodiments, the techniques described herein relate to a process in which processing a thermoformed member includes heating the thermoformed member.

[0018] In some embodiments, 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 (joined) to each other to connect the thermoformed member and the overmolded member.

[0019] In some embodiments, the techniques described herein relate to beams in which the thermoformed members are not made of steel, aluminum, or other metallic materials.

[0020] In some embodiments, the technology described herein relates to a beam in which the overmolded member includes one or more mounting holes or one or more mounting slots.

[0021] In some embodiments, the techniques described herein relate to a beam, wherein the overmolded member includes one or more overmolding straps for at least partially enclosing the thermoformed member.

[0022] In some embodiments, the technology described herein relates to a beam, where the beam is a cross-vehicle beam.

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

[0024] In some aspects, the technology described herein relates to a beam in which the thermoformed member has a U - cross - sectional shape.

[0025] In some aspects, the process of manufacturing a structural element includes controlling the temperature during thermoforming and overmolding to a specific range that optimizes the bond between a first thermoplastic material and a second thermoplastic material, and the specific temperature range is between 200°C and 250°C.

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

[0027] In some aspects, a method of recycling or reusing materials from a structural element includes disassembling the structural element at the end of its life cycle and separating the fiber material and thermoplastic material for reuse or recycling.

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

[0029] In some aspects, the process of manufacturing a structural element includes customizing the properties of the structural element to be particularly suitable for use in an environment selected from the group consisting of electric vehicles, hybrid vehicles, aerospace, and marine environments.

Brief Description of the Drawings

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

[0031] [Figure 1] This is a perspective view of one embodiment of a beam, with several examples.

[0032] [Figure 2] Here are some examples of blanks used to form beams.

[0033] [Figure 3] This is a perspective view of thermoformable components, showing several examples.

[0034] [Figure 4] This is a perspective view of one embodiment of a beam, with several examples.

[0035] [Figure 5] This is a diagram illustrating how to form a beam, using several examples.

[0036] [Figure 6] This is an alternative diagram of the method shown in Figure 5, with several examples.

[0037] [Figure 7] This is a diagram illustrating how to form a beam, using several examples.

[0038] [Figure 8] This is an alternative diagram of the method shown in Figure 7, with several examples.

[0039] [Figure 9] This diagram illustrates methods for forming beams, such as the beam shown in Figure 1, using several examples. [Modes for carrying out the invention]

[0040] Generally speaking, one or more aspects of this disclosure relate to beams for vehicles and methods for forming beams. The beam structures and methods disclosed herein have general applicability in many products and industries, including automotive, recreation, shipping, boating, aerospace, and robotics. For ease of explanation, beams and methods are discussed in relation to vehicles, specifically vehicle crossbeams. However, the applications of the beams disclosed herein and the methods for forming these beams are not limited to vehicles and have applicability in many industries. Furthermore, these methods may be used for purposes other than beams to form other structural shapes. These manufacturing methods can create non-beam shapes, such as complex 3D surface shapes, in applications including, but not limited to, console structures, steering column support brackets, trim support brackets, or localized reinforcements for trimming components.

[0041] Traditional methods for vehicle crossbeams have relied on steel or other metals, resulting in heavier beams. Further bonding or mounting components to the steel or other metal requires additional operations or components. These drawbacks have led to increased costs, longer manufacturing times, and inefficiencies in vehicles, particularly in electric vehicles where weight is critical.

[0042] To address some of the shortcomings 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 for producing this beam provide a low-weight beam with sufficient structural integrity.

[0043] The beam includes a thermoformable member, which may be called a molded member, and an overmolded portion. In certain embodiments, the thermoformable member starts the process as a blank shape. In certain embodiments, the blank shape is cut from a material sheet. The material used for the thermoformable member may be a first material. The first material may be a combination material comprising a fibrous material and a thermoplastic material. For example, the first material may be a fibrous material into which a thermoplastic material is injected, impregnated, or injected.

[0044] In certain embodiments, the blank shape body may then be heated. In certain embodiments, the blank shape body may be heated via a double-sided heating device so that the material is heated uniformly on both sides. The blank shape body is then inserted into a first tool. The first tool may be a compression molding tool, a thermoforming tool, an injection molding tool, or any combination thereof. The blank shape body may then be formed into a molded member. The molded member in this embodiment has a U-shaped cross-section, but may have a different shape. In some embodiments, the molded member remains in the first tool, while in other embodiments of the process, the molded member is removed from the first tool.

[0045] Once the molded part is removed from the first tool, overmolding may be performed with a second tool, or the molded part may be reinserted into the first tool. The molded part may undergo secondary operations before being inserted into the second tool used for overmolding and / or before being reinserted into the first tool. Secondary operations may include, for example, removing excess material on a computer numerical control (CNC) machine, adding mounting holes or mounting slots, or other similar operations.

[0046] If the molded part remains on the first tool, overmolding is performed with the same tool (e.g., the first tool) that was used for thermoforming. Overmolding is the process of forming one material on top of another material, or after another material has been formed. Overmolding may involve injecting a second material, which is an injection-molded material, into the first tool. The second material used for injection molding is selected to bond directly to the molded part. The material used for injection molding may be the same material as the thermoplastic material.

[0047] Once the molded member is overmolded with injection molding material, it is removed from the first or second tool. In certain embodiments, the overmolded member may undergo additional secondary operations at this point.

[0048] Figure 1 is a diagram of one embodiment of the beam 100 according to this application. The beam 100 comprises a thermoformed member 120, which may also be referred to herein as a molded member 120, and an overmolded portion 140. The thermoformed member 120 is joined to the overmolded portion 140. The molded member 120 may be made from a fibrous material and a thermoplastic material. The fibrous material may be carbon fiber, glass fiber, flax, aramid, Kevlar®, any various other fibrous materials, or any combination thereof. The thermoplastic material may be polypropylene homopolymer, polypropylene copolymer, nylon homopolymer, nylon copolymer, or various other thermoplastic materials. The overmolded portion 140 may reinforce, support, or structurally assist the molded member 120 to produce a stronger beam 100. The overmolded portion 140 may be made from any of the thermoplastic materials used in 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 mechanisms 102. The mounting mechanisms 102 may be formed directly on the thermoformed member 120 or the overmolded portion 140. The mounting mechanisms 102 may be mounting holes, mounting slots, engagement mechanisms, offset mechanisms, other mechanisms that enable the beam 100 to be mounted on the vehicle, or other components that are attached to the beam 100.

[0050] Figure 2 is a diagram of a blank shape 110. In a particular embodiment, the blank shape 110 is cut from a material sheet. The blank shape 110 is formed into a molded member 120. There may be a single blank shape 110 used to form the molded member 120, or there may be multiple blank shapes 110 used to form the molded member 120. The blank shape 110 may include a plurality of positioning holes 112 used to position the blank shape 110 within a tool. The blank shape 110 may further include one or more notches 104. One or more notches 104 may help the blank shape 110 form the molded member when it is thermoformed within a tool.

[0051] Figure 3 shows a molded member 120. The molded member 120 may have a U-shaped cross-section with 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 does not bend, while the top surface 122 and bottom surface 126 bend. The bends 128 may also be in the Z direction such that the front surface 124 bends, while the top surface 122 and bottom surface 126 do not bend. Furthermore, the bends 128 may be a combination of X-bends and Y-bends, or may include a bend in the X direction.

[0052] In certain embodiments, the molded member 120 may have a thickness between 2.2 and 2.4 mm, between 2 mm and 3 mm, or between 1.5 and 3.5 mm. In certain embodiments, the molded member may have a density of 1.4 g / cm³. 3 ~1.5g / cm 3 Up to that point, 1.3 g / cm³ 3~1.6g / cm 3 Until then, or 1.2 g / cm³ 3 ~1.7g / cm 3 The material density may be between 50 GPa and 60 GPa, between 45 GPa and 65 GPa, or between 40 GPa and 70 GPa.

[0053] Figure 4 shows a beam 100 including a molded member 120 and an overmolded portion 140. The beam 100 may be a cross member for a vehicle. The overmolded portion 140 may include a plurality of overmolding straps 142. The molded member 120 is directly bonded to the overmolded portion 140, but in certain embodiments, the overmolding straps 142 may function to completely enclose the molded member 120.

[0054] Figure 5 is a diagram of a method 200 for forming a beam 100. Method 200 begins in step 202, in which a first material is cut into a blank shape 110. The first material may be any of the previously discussed combinations of fibrous material and thermoplastic material. Step 202 may include cutting a single blank shape 110 or a plurality of blank shapes 110. The first material may be cut by laser, water jet, die, or other suitable method.

[0055] Step 204 includes heating the blank shape 110. In certain embodiments, the blank shape 110 may be heated in a double-sided oven or any other type of oven. Heat can make the material more malleable so that the material is easier to form.

[0056] Step 206 includes thermoforming a blank shape(s) 110 into a molding member 120. Step 206 may include several substeps, such as preheating a first tool, placing the blank shape(s) 110 into the first tool, and applying pressure, compression, or heat to form the blank shape(s) 110 into the molding member 120. Once the blank shape(s) 110 are formed, the first tool may remain closed or open prior to step 208.

[0057] Step 208 includes injecting a second material into a first tool. The second material may be any injection-molded material, such as a polypropylene homopolymer, polypropylene copolymer, nylon homopolymer, or nylon copolymer. Step 208 may include bonding the injected second material to the molded member 120. Bonding may occur spontaneously depending on the material selection, i.e., if the thermoplastic material is the same as the second material.

[0058] Please understand that Method 200 may include all or part of steps 202-208. Furthermore, Method 200 may include additional steps.

[0059] Figure 6 is an alternative diagram of part of Method 200. The Method includes step 206, in which a blank shape 110 is thermoformed into a molding member 120. In this embodiment, step 206 includes substep 206.1, which involves placing the blank shape 110 into a first tool, and substep 206.2, which involves compressing the blank shape 110 into a molding member 120. Step 208 includes injecting a second material into the first tool, i.e., overmolding the molding member 120.

[0060] Figure 7 is a diagram of a method 300 for forming a beam 100. Method 300 begins in step 302, in which a first material is cut into blank shapes 110. The first material may be any of the previously discussed combinations of fibrous material and thermoplastic material. 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 blank shape 110. In certain embodiments, the blank shape may be heated in a double-sided oven. The heat may make the material more malleable so that the material is easier to form. Step 304 may be the same as or similar to step 204.

[0062] Step 306 includes thermoforming a blank shape(s) 110 into a molded member 120. Step 306 may include several substeps, such as preheating a first tool, placing the blank shape(s) 110 into the first tool, and applying pressure, compression, or heat to form the blank shape(s) 110 into the molded member 120. Once the blank shape(s) 110 is formed, the first tool is opened to release the molded member 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 completing a secondary operation on the molded member 120. The secondary operation may include removing excess material from the molded member 120. The secondary operation may further include adding holes, slots, or other mechanisms to the molded member 120. In some embodiments, step 308 may be optional for method 300.

[0064] Step 310 includes positioning or inserting the molded member 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 a second tool. The second material may be any injection-molded material such as a thermoplastic resin and / or polypropylene homopolymer, polypropylene copolymer, nylon homopolymer, nylon copolymer, or a combination thereof. Step 312 may include bonding the injected second material to the molded member 120. Bonding may occur spontaneously depending on the material selection, i.e., if the thermoplastic material is the same as the second material.

[0066] Please understand that Method 300 may include all or part of steps 302-312. Furthermore, Method 300 may include additional steps.

[0067] Figure 8 is an alternative diagram of part of Method 300. The Method includes step 306, which thermoforms a blank shape 110 into a molded member 120. In this embodiment, step 306 includes substep 306.1, which includes placing the blank shape 110 into a first tool, and substep 306.2, which includes compressing the blank 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 the second material into the second tool. The second material for forming 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 any other material including a thermoplastic resin or thermoplastic composition. Since the first and second materials share a common thermoplastic composition, bonding between the first and second materials may occur spontaneously or naturally after the second material has been injected into the second tool. Once the injection molding in step 312 is complete, the beam 100 is removed from the second tool.

[0068] Figure 9 is a diagram of method 400 for forming beam 100. Method 400 may be similar to method 200 or method 300 and may share any of the steps described above. Method 400 begins in step 402, in which a first material is cut into blank shapes 110. The first material may be any of the previously discussed combinations of fibrous material and thermoplastic material. 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 step 202 or step 302.

[0069] Step 404 includes heating the blank shape 110. In certain embodiments, the blank shape may be heated in a double-sided oven or any other type of oven. The heat may make the material more malleable so that the material is easier to form. Step 404 may be the same as or similar to step 204 or step 304.

[0070] Step 406 includes thermoforming a blank shape(s) 110 into a molding member 120. Step 406 may include several substeps, such as preheating a first tool, placing the blank shape(s) 110 into the first tool, and applying pressure, compression, or heat to form the blank shape(s) 110 into the molding member 120. Once the blank shape(s) 110 is formed, the first tool is opened to release the molding member 120. Step 406 may be the same as or similar to step 206 or step 306.

[0071] Step 408 includes completing a secondary operation on the molded member 120. The secondary operation may include removing excess material from the molded member 120. The secondary operation may further include adding holes, slots, or other mechanisms to the molded member 120.

[0072] Step 410 includes heating the molded member 120. In certain embodiments, the molded member 120 may be heated in a double-sided oven. The heat may promote a strong bond and / or adhesion between the molded member 120 and the material injected to bond to the molded member 120. Additionally and / or optionally, adhesion-enhancing processes such as plasma or flame treatment may be included in step 410 to further strengthen the bond.

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

[0074] Step 414 includes injecting a second material into a second tool. The second material may be any injection-molded material such as a thermoplastic resin and / or a polypropylene homopolymer, polypropylene copolymer, nylon homopolymer, nylon copolymer, or any combination thereof. Step 414 may include bonding the injected second material to the molded member 120. Bonding may occur spontaneously depending on the choice of materials, i.e., if the thermoplastic material is the same as the second material. For example, the first material may include a thermoplastic composition. The second material may include any other material including a thermoplastic resin or thermoplastic composition. Since the first and second materials share a common thermoplastic composition, bonding between the first and second materials may occur spontaneously or naturally after the second material has been injected into the second tool.

[0075] Please understand that Method 400 may include all or part of steps 402-414. Furthermore, Method 400 may include additional steps.

[0076] In some cases, precise temperature control is provided to achieve optimal material properties and bond strength. Thermoforming and overmolding processes are carried out within a specific temperature range of 200°C–250°C, which has been shown to optimize, or at least strengthen, the bond between the first and second thermoplastic materials. This temperature range aims to ensure that the thermoplastic materials are sufficiently malleable to form a strong bond without degrading the fibrous materials.

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

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

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

[0080] In some cases, the properties of structural elements are customized to meet the specific requirements of various applications. For example, modifications to properties such as flexibility, rigidity, or thermal insulation can be made to adapt structural elements for use in electric vehicles where weight and battery efficiency may be critical, or in aerospace applications where a high strength-to-weight ratio may be required. Examples

[0081] Therefore, some embodiments may include one or more of the following examples.

[0082] Example 1. A process for manufacturing a structural element, comprising: heating a blank shape body comprising a composite material comprising fibers and a first thermoplastic material; thermoforming the blank shape body using a tool to form a thermoformable member; and overmolding the thermoformable member with a molding material comprising a second thermoplastic material using a tool to form a structural element, wherein the first thermoplastic material and the second thermoplastic material are bonded to each other by overmolding the thermoformable member.

[0083] Example 2. The process according to Example 1, further comprising cutting a composite material sheet to form a blank shape.

[0084] Example 3. The process according to Example 1 or 2, wherein thermoforming of a blank shape comprises inserting the blank shape into a tool and compressing the blank shape into a thermoforming member.

[0085] Example 4. Overmolding a thermoformable member is a process according to any one of Examples 1 to 3, comprising injecting a molding material into a tool.

[0086] Example 5. The process according to any one of Examples 1 to 4, wherein the thermoformed member has a first shape, and by overmolding, the molded material has a second shape different from the first shape.

[0087] Example 6. The process according to any one of Examples 1 to 5, wherein the molding material is selected from the group including polypropylene homopolymer, polypropylene copolymer, nylon homopolymer, nylon copolymer, and combinations thereof.

[0088] Example 7. A process for manufacturing a structural element, comprising: heating a blank shape body comprising a composite material comprising fibers and a first thermoplastic material; thermoforming the blank shape body to form a thermoformable member using a first tool; and overmolding the thermoformable member with a molding material comprising a second thermoplastic material to form a structural element using a second tool different from the first tool, wherein the first thermoplastic material and the second thermoplastic material are bonded to each other by overmolding the thermoformable member.

[0089] Example 8. The process described in Example 7, wherein the first tool is a compression molding tool, a thermoforming tool, or an injection molding tool.

[0090] Example 9. The process described in Example 7 or 8, wherein the structural element is a cross vehicle beam.

[0091] Example 10. The process according to any one of Examples 7 to 9, further comprising cutting a composite material sheet to form a blank shape.

[0092] Example 11. The process according to any one of Examples 7 to 10, further comprising processing a thermoformable member and inserting the thermoformable member into a second tool.

[0093] Example 12. The process described in Example 11, wherein processing the thermoformed member includes removing excess material from the thermoformed member or adding mounting holes or mounting slots to the thermoformed member.

[0094] Example 13. The process according to Example 11 or 12, wherein processing the thermoformable member includes heating the thermoformable member.

[0095] Example 14. Overmolding a thermoformable member is a process according to any one of Examples 7 to 13, comprising injecting a molding material into a second tool.

[0096] Example 15. A thermoformable member comprising a fibrous material and a first thermoplastic material, and an overmolded member connected to the thermoformable member, wherein the overmolded member comprises a second thermoplastic material, and the first thermoplastic material and the second thermoplastic material are joined to each other to form a beam connecting the thermoformable member and the overmolded member.

[0097] Example 16. The thermoformable member is the beam described in Example 15, which does not contain steel, aluminum, or any other metallic material.

[0098] Example 17. The beam according to Example 15 0r 16, wherein the overmolded member comprises one or more mounting holes or one or more mounting slots.

[0099] Example 18. The beam according to any one of Examples 15 to 17, wherein the overmolded member comprises one or more overmolding straps for at least partially enclosing the thermoformed member.

[0100] Example 19. A beam according to any one of Examples 15 to 18, wherein the fibrous material comprises carbon, aramid, or natural fibers, and the first thermoplastic material and the second thermoplastic material comprise nylon or a thermoplastic material, or a mixture thereof.

[0101] Example 20. The thermoformable member is a beam according to any one of Examples 15 to 19, having a U-shaped, C-shaped, or I-shaped cross-section.

[0102] Example 21. A beam comprising a molded member having a blank shape of fibrous material into which a thermoplastic material formed into a first shape has been injected, and an overmolded member having an injection-molded material joined to the molded member.

[0103] Example 22. The beam is a cross vehicle beam, as described in Example 21.

[0104] Example 23. The beam according to Example 21 or 22, wherein the first shape is a U-shaped beam.

[0105]

[0106] Example 24. A beam according to any one of Examples 21 to 23, wherein the fibrous material is carbon fiber and the thermoplastic material is nylon.

[0107] Example 25. The injection molding material is nylon, as described in any one of Examples 21 to 24.

[0108] Example 26. The beam according to any one of Examples 21 to 25, wherein the injection molding material is the same material as the thermoplastic material, and the injection molding material is directly bonded to the thermoplastic material during the injection molding process.

[0109] Example 27. A method for forming a beam, comprising: cutting a first material into a blank shape; heating the blank shape; thermoforming the blank shape into a molding member using a first tool; inserting the molding member into an injection molding tool; injecting a second material into the injection molding tool; and directly joining the first material to the second material.

[0110] Example 28. The method of Example 27, further comprising injecting a second material into an injection molding tool to directly bond the first material to the second material.

[0111] Example 29. A method for forming a beam, comprising: cutting a first material into a blank shape; heating the blank shape; thermoforming the blank shape into a molding member with a first tool; overmolding the molding member with a second material in the first tool; and directly joining the first material to the second material.

[0112] Example 30. The method according to Example 29, wherein further overmolding the molded member with a second material includes directly bonding the second material to the molded member.

[0113] Example 31. A structural beam comprising a thermoformed member and an injection-molded overmolded member, wherein the thermoformed member comprises a fibrous material and a thermoplastic material, and the injection-molded overmolded member comprises a thermoplastic material.

[0114] The foregoing disclosure is not intended to limit the disclosure to the very form or specific field of use disclosed. Therefore, it is intended that various alternative embodiments and / or variations of the disclosure, whether expressly described or implied herein, are possible in light of the disclosure. Having described embodiments of the disclosure in this manner, those skilled in the art will recognize that modifications can be made in form and detail without departing from the scope of the disclosure. Therefore, the disclosure is limited only by the claims.

[0115] In the aforementioned specification, the disclosure has been described with reference to specific embodiments. However, as those skilled in the art will understand, the various embodiments disclosed herein can be modified or implemented in various other ways without departing from the spirit and scope of the disclosure. Therefore, this description should be considered illustrative and is intended to teach those skilled in the art how to create and use various embodiments of the disclosed materials, elements, and crosscar beams. It should be understood that the forms of disclosure shown and described herein should be interpreted as representative embodiments. Equivalent elements, materials, processes, or steps can be substituted for those representatively shown and described herein. Furthermore, certain features of the disclosure can be utilized independently of the use of other features, as will become apparent to those skilled in the art after benefiting from this description of the disclosure. Expressions such as “including,” “comprising,” “incorporating,” “consisting of,” “have,” and “is” used to describe and claim this disclosure are intended to be interpreted in a non-exclusive manner, that is, to allow for the existence of items, components, or elements not expressly described. References to singular forms should be interpreted as relating to plural forms as well.

[0116] Furthermore, the various embodiments disclosed herein should be interpreted in an illustrative and descriptive sense and not in any way as limiting the disclosure. All references to joining (e.g., attachment, fastening, coupling, connection, etc.) are used solely to aid the reader's understanding of the disclosure and should not result in any limitation with respect to the location, orientation, or use of the systems and / or methods disclosed herein. Accordingly, where there is a reference to joining, it should be interpreted broadly. Moreover, such references to joining do not necessarily imply that the two elements are directly connected to each other. In addition, but not limited to, all numerical terms such as “first,” “second,” “third,” “primary,” “secondary,” and “main,” or any other common terms and / or numerical terms, should also be interpreted solely as identifiers to aid the reader’s understanding of the various elements, embodiments, variations, and / or modifications of this disclosure, and in particular, should not create any limitation in relation to or with respect to any other element, embodiment, variation, and / or modification with respect to the order or priority of any element, embodiment, variation, and / or modification.

[0117] It should also be understood that one or more of the elements shown in the drawings / figures may be implemented in a more separated or integrated manner to be useful for a particular application, or may be removed or rendered as non-functional in certain cases.

Claims

1. A process for manufacturing structural elements, A step of heating a blank shape, wherein the blank shape comprises a composite material comprising fibers and a first thermoplastic material, The steps include: using a tool to thermoform the blank shape to form a thermoformable member; A step of overmolding the thermoformed member with a molding material comprising a second thermoplastic material to form the structural element using the tool, wherein the first thermoplastic material and the second thermoplastic material are bonded to each other by overmolding the thermoformed member. A process that includes this.

2. The process according to claim 1, further comprising the step of cutting a composite material sheet to form the blank shape.

3. The step of thermoforming the blank shape is: Inserting the blank shape into the tool, The process according to claim 1, comprising compressing the blank shape into the thermoforming member.

4. The process according to claim 1, wherein the step of overmolding the thermoformable member includes injecting the molding material into the tool.

5. The process according to claim 1, wherein the thermoformed member has a first shape, and by overmolding, the molded material has a second shape different from the first shape.

6. The process according to claim 1, wherein the molding material is selected from the group including polypropylene homopolymer, polypropylene copolymer, nylon homopolymer, nylon copolymer, and combinations thereof.

7. A process for manufacturing structural elements, A step of heating a blank shape, wherein the blank shape comprises a composite material comprising fibers and a first thermoplastic material, A step of thermoforming the blank shape body to form a thermoformable member using a first tool, A step of overmolding the thermoformable member with a molding material comprising a second thermoplastic material to form the structural element, using a second tool different from the first tool, wherein the first thermoplastic material and the second thermoplastic material are bonded to each other by overmolding the thermoformable member. A process that includes this.

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 cross vehicle beam.

10. The process according to claim 7, further comprising the step of cutting a composite material sheet to form the blank shape.

11. The steps include processing the thermoformed member, The steps include inserting the thermoforming member into the second tool, The process according to claim 7, further comprising:

12. The process according to claim 11, wherein the step of processing the thermoformed member includes removing excess material from the thermoformed member or adding mounting holes or mounting slots to the thermoformed member.

13. The process according to claim 12, wherein the step of processing the thermoformed member includes heating the thermoformed member.

14. The process according to claim 12, wherein the step of overmolding the thermoformable member includes injecting the molding material into the second tool.

15. A thermoformable member comprising a fibrous material and a first thermoplastic material. An overmolding member connected to the thermoforming member, the overmolding member comprising a second thermoplastic material, Equipped with, The first thermoplastic material and the second thermoplastic material are bonded together to connect the thermoforming member and the overmolded member. beam.

16. The beam according to claim 15, wherein the thermoformed member does not contain steel, aluminum, or any other metallic material.

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

18. The beam according to claim 15, wherein the overmolding member comprises one or more overmolding straps for at least partially enclosing the thermoformed member.

19. The beam according to claim 15, wherein the fibrous material comprises carbon, aramid, or natural fibers, and the first thermoplastic material and the second thermoplastic material comprise nylon, a thermoplastic material, or a mixture thereof.

20. The beam according to claim 15, wherein the thermoformable member has a U-shaped cross-section, a C-shaped cross-section, or an I-shaped cross-section.

21. A molded member comprising a blank-shaped body of fibrous material impregnated with a thermoplastic material formed into a first shape, An overmolded member comprising injection-molded material bonded to the aforementioned molded member, A beam equipped with a beam.

22. The beam according to claim 21, wherein the beam is a cross vehicle beam.

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 fibrous material is carbon fiber and the thermoplastic material is nylon.

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

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

27. A method for forming a beam, The first step is to cut the material into a blank shape, The steps include heating the blank shape body, The first step is to thermoform the blank shape into a molding member using a first tool, The steps include inserting the molded member into an injection molding tool, The steps include injecting a second material into the injection molding tool, The steps include directly bonding the first material to the second material, Methods that include...

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

29. A method for forming a beam, The first step is to cut the material into a blank shape, The steps include heating the blank shape body, The first step is to thermoform the blank shape into a molding member using a first tool, The steps include overmolding the molded member with the second material in the first tool, The steps include directly joining the first material to the second material, Methods that include...

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

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

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