Injection moulded reinforcement member

Abstract

The present invention relates to a system comprising a structure with a cavity with a longitudinal extension and a reinforcement member having: - a longitudinal extension and a transverse extension, - a multitude of longitudinal ribs, each provided in a plane along a longitudinal direction and the transverse direction, - a multitude of transverse ribs each extending in the transverse direction, wherein the longitudinal ribs and the transverse ribs form a multitude of channels, extending in the transverse direction, wherein in each channel a frame is provided.

Description

[0001] Injection moulded reinforcement member

[0002] The present invention relates to a system comprising a structure with a cavity with a longitudinal extension and a reinforcement member having: a longitudinal extension and a transverse extension, a multitude of longitudinal ribs, each provided in a plane along a longitudinal direction and the transverse direction, a multitude of transverse ribs each extending in the transverse direction, wherein the longitudinal ribs and the transverse ribs form a multitude of channels, extending in the transverse direction, wherein in each channel a frame is provided.

[0003] Such a system is for example known from US 10 926 804, which is, however, limited in its shock absorption characteristics.

[0004] There is therefore a constant need to improve such systems.

[0005] The problem is attained with a system comprising a structure with a cavity with a longitudinal extension and a reinforcement member having: a longitudinal extension and a transverse extension, a multitude of longitudinal ribs, each provided in a plane along a longitudinal direction and the transverse direction, a multitude of transverse ribs each extending in the transverse direction, wherein the longitudinal ribs and the transverse ribs form a multitude of channels, extending in the transverse direction, wherein in each channel a frame is provided and the wall thickness of the longitudinal ribs is not constant in its transverse direction.

[0006] The disclosure made regarding this subject matter also applies to the other subject matters and vice versa. Subject matter disclosed according to this subject matter can be incorporated in other subject matters and vice versa.

[0007] The present invention relates to a system comprising a structure with a cavity. The structure is preferably part of a vehicle, for example a rocker, preferably a rocker next to a battery case of a vehicle. The cavity of the structure comprises a longitudinal axis. This longitudinal axis is preferably parallel to the longitudinal direction of the vehicle. The system further comprises a reinforcement member which is provided within the cavity of the structure. The reinforcement member has a longitudinal extension, preferably its longest extension. The longitudinal extension is preferably parallel to the longitudinal axis of the structure. The reinforcement member also comprises a transverse extension, which is provided at an angle, preferably a 90° angle relative to the longitudinal extension. The transverse extension of the reinforcement member is essentially the same as the transverse extension of the cavity of the structure, preferably slightly smaller, because preferably a gap is provided between the reinforcement member and the inner walls of the cavity.

[0008] According to the invention, the reinforcement member comprises multitude of longitudinal ribs, each provided in a plane along a longitudinal direction and the transverse direction. Theses ribs are preferably parallel to each other. The ribs are preferably stacked in a vertical direction.

[0009] Further, the reinforcement member comprises a multitude of transverse ribs each extending in the transverse direction of the reinforcement member. Each rib is preferably provided vertically. The transverse ribs are provided at an angle relative to the longitudinal extension. The angle may be 90°, but also a different angle between 1 and 179°.

[0010] Together, the longitudinal ribs and the transverse ribs form a multitude of channels, extending in the transverse direction. For example, two longitudinal ribs and two transverse ribs or one longitudinal rib and two transverse ribs may form a channel. The length channels preferably extend in a horizontal direction and form an array of channels with multiple rows and columns. The distance between two opposite transverse ends of the reinforcement member defines the length of the channel.

[0011] In each channel a frame is provided, which reduces the cross section of the channel locally. The frame preferably extends only along a small section of the length of the channel. Relative to its length, the frame is preferably provided in the middle. The frame may be provided in a symmetry plane of the reinforcement member.

[0012] According to the invention, the wall thickness of the longitudinal ribs is not constant in its transverse direction. Preferably, the wall thickness decreases towards the transverse ends, preferably both opposite ends, of the reinforcement member, preferably from the middle towards the transverse end. The resulting angle due to the change in wall thickness is preferably larger than the draft angle required for injection moulding. Preferably, the angle is larger than 1°, preferably 2°, more preferably 3°, even more preferably 4° or larger. It has been found that due to the change in wall thickness, the shock absorption has been increased.

[0013] Preferably, the wall thickness of the transverse ribs is not constant in the transverse direction. Preferably, the wall thickness decreases towards the transverse ends, preferably both opposite ends, of the reinforcement member, preferably from the middle towards the transverse end. The resulting angle due to the change in wall thickness is preferably larger than the draft angle required for injection moulding. Preferably, the angle is larger than 1°, preferably 2°, more preferably 3°, even more preferably 4° or larger.

[0014] It has been found that due to the change in wall thickness, the shock absorption has been increased.

[0015] According to another or preferred embodiment of the present invention, the reinforcement member is made of material comprising a polymeric material, preferably Polyamide (PA), more preferably PA6.

[0016] The disclosure made regarding this subject matter also applies to the other subject matters and vice versa. Subject matter disclosed according to this subject matter can be incorporated in other subject matters and vice versa.

[0017] According to this subject matter of the present invention, the reinforcement member comprises a polymeric material. Preferably, the reinforcement member is injection moulded.

[0018] Preferably, the polymeric material comprises a filler, more preferably a filler to improve toughness and / or ductility. A filler that improves the strength, like fibers is not desired and should not be added.

[0019] Preferably, the polymeric material comprises an elastomeric material, preferably in an amount of 20 weight%. A material that behaves rubber-like is preferably a desirable elastomeric material. Such an elastomeric material can be added as a filler.

[0020] Preferably, the polymeric material comprises impact modifiers with a TG < 45°C. Such an impact modifier can be added as a filler. Preferably, the reinforcement member is made of a polymeric material with at least one of the following properties:

[0021] Tensile Modulus > 1500 MPa

[0022] Tensile elongation at break >50%

[0023] Charpy notched impact strength 80 - 100 kJ / m2.

[0024] According to a preferred embodiment of the present invention the reinforcer is attached to structure with adhesive means, preferably one or more patches. The adhesive means preferably reduce noise for example due to rattling and / or reduce fatigue of the reinforcement member. The adhesive means preferably do not provide stability.

[0025] Preferably, there is a gap between the structure and the reinforcer.

[0026] In a preferred embodiment, the cross section is rectangular, square or triangular.

[0027] The inventive system is suitable for a vehicle, especially an automotive vehicle, preferably an electrically driven automotive vehicle.

[0028] Another subject matter of the present invention is therefore a vehicle comprising the inventive system.

[0029] The disclosure made regarding this subject matter also applies to the other subject matters and vice versa. Subject matter disclosed according to this subject matter can be incorporated in other subject matters and vice versa.

[0030] The system is particularly useful to protect a batter case needed for an electrically driven vehicle, preferably against a side crash.

[0031] Preferably, the system is preferably a reinforced rocker.

[0032] The invention is now explained according to the Figures. These explanations are only exemplary and do not limit the scope of protection.

[0033] Figs. 1 - 3 show an embodiment of reinforcement member 1

[0034] Figs. 4 and 5 show a load analysis of the reinforcement member 1 Figs. 6 and 7 show details of the reinforcement member 1

[0035] Figs. 1 - 3 show an embodiment of the reinforcement member 1. The reinforcement member is placed into the cavity of a structural element (not depicted). The reinforcement member 1 has a longitudinal extension LD, which preferably coincides with the longitudinal extension of the structural element, for example a rocker at the longitudinal side of a vehicle. The reinforcement member also has a transverse extension TD which is the extension perpendicular to the longitudinal extension. The transverse extension is for example the width of the reinforcement member 1. Further, the reinforcement member 1 has a second transverse extension, which is for example the height of the reinforcement member 1. The transverse extensions of the reinforcement member 1 preferably are slightly smaller than the dimensions of the cross section of the structural element, so that there is a gap between the structural element and the reinforcement member 1.

[0036] According to the invention, the reinforcement member 1 has at least one, here four, longitudinal rib(s) 2, here four, each having an extension in the longitudinal and transverse direction. In the vehicle, the longitudinal rib 2 is preferably provided in a horizontal plane. In the transverse direction, preferably one transverse end of the longitudinal rib faces towards the side of the vehicle and the opposite transverse end towards the inside of the vehicle, preferably a battery case. The longitudinal ribs 2 are stacked upon each other, preferably in a horizontal direction. The distance between two adjacent longitudinal ribs 2 is in the present example constant. However the person skilled in the art understands that the distance may vary.

[0037] The reinforcement member 1 further comprises a multitude of transverse ribs 3, which are her provided at a 90° angle relative to the longitudinal extension. The transverse ribs 3 have a transverse extension TD, which is preferably equal or slightly smaller than the extension of the structural element is this direction. In the present case the transverse ribs are provided in parallel and equidistantly, but the person skilled in the art understands that this may be different. The transverse ribs 3 may have different angles relative to the longitudinal extension and / or to adjacent transverse ribs may have different distances.

[0038] In the present case two adjacent longitudinal ribs 2 and two adjacent transverse ribs form a channel 4, that preferably extends along the entire transverse extension of the reinforcement member 1. In the present case the, channel 4 has square cross-section, but the cross section can also be rectangular or triangular. The channel can be utilized to guide a coating material for coating the structural element and / or to guide a cooling medium after injection moulding. The size and / or the shape of the channels 4 is an optimization taking the flow of at least one of the media into account and the required stability of the reinforcement member.

[0039] At one distal end, the reinforcement member 1 may be provided with a cover 6.

[0040] The reinforcement member 1 is made from a polymeric material, whose main material is preferably Polyamide (PA), more preferably PA6, which more preferably comprises a compound to improve the toughness and / or ductility of the polymeric material. Filler like fibers are preferably not desired.

[0041] Fig. 2 is a sectional view along the cut A-A. It can be seen that the thickness of the longitudinal ribs the transverse extension is not constant, but decreases from a maximum thickness, here in the middle, here continuously, towards the ends in the transverse direction. The resulting inclination of the sides of the ribs is larger than the inclination needed to entformn the reinforcement member 1 from a mould.

[0042] From Figs. 2 and 3 it can be seen that in each channel a frame 5 is provided, which extends along the entire inner circumference of the channel 4 and which reduces locally the dimension the cross section of the channel. In the present case, the frame 5 is provided in the center plane of the reinforcement member 1.

[0043] Figs 4 and 5 show the reinforcement member 1 during a crash, depicted by the large arrow 9. Fist, the load in the reinforcement member 1 increases steeply, until the transverse ends of the longitudinal ribs start to fold (see Fig. 5). During folding, the load still increase but with a significantly reduced slope.

[0044] Fig. 6 show a detail of the reinforcement member 1. Adhesive means 7, are provided to fix the reinforcement member 1 to the structure not to provide additional reinforcement but to reduce noise and / or fatigue of the reinforcement member 1. Fixation means 7 may be provided to further attach the reinforcement member 1 to the structural element.

[0045] Fig. 7 show a detail of the longitudinal rib 2. The resulting angle a from the change in thickness is larger than the angle needed to remove the reinforcement member 1 from the mould. Reference signs:

[0046] 1 Reinforcement member

[0047] 2 Longitudinal rib

[0048] 3 Transverse rib

[0049] 4 Channel

[0050] 5 Frame

[0051] 6 Cover

[0052] 7 Adhesive means, CBS-patches

[0053] 8 Fixation mean

[0054] 9 load a angle

[0055] LD Longitudinal extension

[0056] TD Transverse extension

Claims

Claims:

1. System comprising a structure with a cavity with a longitudinal extension and a reinforcement member (1) having: a longitudinal extension (LD) and a transverse extension (TD), a multitude of longitudinal ribs (2), each provided in a plane along a longitudinal direction and the transverse direction, a multitude of transverse ribs (3) each extending in the transverse direction, wherein the longitudinal ribs (2) and the transverse ribs (3) form a multitude of channels, extending in the transverse direction, wherein in each channel a frame (5) is provided, characterized in, that the wall thickness of the longitudinal ribs is not constant in its transverse direction (TD).

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

3. System according to one of the preceding claims characterized in, that the wall thickness increases towards the center of the reinforcement member (1).

4. System according to one of the preceding claims or the preamble of claim 1 , characterized in, that reinforcement member is made of material comprising a polymeric material, preferably PA, more preferably PA6.

5. System according to claim 4, characterized in, that it comprises a filler to improve toughness and / or ductility.

6. System according to claims 4 or 5, characterized in, that the material comprises an elastomeric material, preferably in an amount of 20 weight%.

7. System according to claims 4 - 6, characterized in, that material comprises impact modifiers with a TG < 45°C.

8. System according to claims 4 - 7, characterized in, that , that reinforcement member is made of a polymeric material with at least one of the following properties:Tensile Modulus > 1500 MPaTensile elongation at break >50%Charpy notched impact strength 80 - 100 kJ / m2.

9. System according to one of the preceding claims, characterized in, that the reinforcer is attached to structure with adhesive means, preferably one or more patches.

10. System according to one of the preceding claims, characterized in, that there is a gap between the structure and the reinforcer.

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

12. Vehicle comprising a system according to one of the preceding claims.

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