Three dimensional laminate beam structure

Details Three dimensional laminate beam structure Three dimensional laminate beam structure

2000-02-03

2001-08-14

Callo, Laura A. (Department: 3635)

Static structures (e.g., buildings)

Machine or implement

C052S749100, C052S309500, C052S309700, C052S309900, C052S309140, C052S745190, C052S742130, C029S897200, C264S046500, C264S046600, C296S187060, C296S182100, C296S205000, C280S124134, C280S124153

Reexamination Certificate

active

06272809

ABSTRACT:

BACKGROUND OF THE INVENTION
For various applications, such as in the automotive industry, it is desirable to reinforce a structural section. One approach has been to use a polymer structural foam material for such reinforcement. In some of these applications, however, because of the location or geometry of the part being reinforced, it is difficult to accomplish the intended reinforcement.
Hydra-formed metal sections, for example, may have curved three-dimensional geometry. As a result, reinforcing the section or component is very difficult because the location of the hydra-formed section that is critical and decides the overall performance of the component, is often the section located at a major discontinuity “notch” or curvature. One such part that presents reinforcement problems is a vehicle control arm assembly.
SUMMARY OF THE INVENTION
An object of this invention is to provide a reinforced beam of curved geometry.
A further object of this invention is to provide techniques for reinforcing such a beam.
In accordance with this invention the beam is a hollow curved structure. A pre-molded foam core is inserted into the hollow structure spaced from at least one inside wall of the hollow structure. A polymer is pumped in and around the foam core insert so that after curing the polymer bonds to the inside wall of the structure.
In a preferred practice of the invention the structure is a hydra-formed metal section, such as a vehicle control arm assembly. The pre-shaped foam insert core is preferably made of a lightweight material to minimize the weight of the final laminate beam formed by the invention.
Preferably, the foam core is of the same shape as the hollow interior of the part being reinforced. Flanges, however, may be provided at the outer ends of the core to fit against the inner surfaces of the part being reinforced so as to properly self-locate the insert within the part. Where the part has one or more holes extending through it, the insert core may have aligned holes or passageways so that the foam can be inserted by being pumped through the holes in the part and then flow into the empty space or chamber between the outer surface of the insert and the inner surface of the part with flow being facilitated by means of the holes in the core.


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patent: 5866052 (1999-02-01), Muramatsu
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patent: 59-77973 (1984-05-01), None
patent: 63-203481 (1988-08-01), None

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