Reinforced body in white and method of making and using the same
View Patent ↗A structural body of a vehicle can comprises: a hollow metal component comprising walls that define a channel, wherein the metal component has a metal component length, and wherein the metal component is selected from the group consisting of beam, rail, pillar, chassis, floor rocker, and cross-bar, combinations comprising at least one of the foregoing; and a plastic-metal hybrid reinforcement having a cavities therethrough, and a metal support having greater than or equal to 3 walls forming a support channel. The plastic element is located in the support channel wherein the reinforcement is located in the component channel.
1. A structural body of a vehicle, comprising:
a hollow structural vehicle component comprising walls that define a component channel, wherein the vehicle component has a component length, and wherein the vehicle component is selected from the group consisting of bumper beam, rail, pillar, chassis, floor rocker, and cross-bar, combinations comprising at least one of the foregoing; and
a reinforcement comprising a plastic element having a honeycomb structure, and a metal support having greater than or equal to 3 walls forming a support channel;
wherein the plastic element is located in the support channel; and
wherein the reinforcement is located in the component channel.
2. The structural body of claim 1 , wherein the honeycombs are filled.
3. The structural body of claim 1 , wherein the plastic element comprises a thermoplastic.
4. The structural body of claim 1 , wherein the plastic element further comprises fiber reinforced thermoplastic.
5. The structural body of claim 1 , wherein the reinforcement has a reinforcement length that is less than or equal to 80% of the component length.
6. The structural body of claim 1 , wherein the reinforcement length is 10% to 35% of the component length.
7. The structural body of claim 1 , wherein the plastic element has a hollow honeycomb structure with a hexagonal comb geometry, and has a length of 150 mm to 350 mm.
8. The structural body of claim 1 , wherein the plastic element has a hollow honeycomb structure with a hexagonal comb geometry, and has a length of 500 mm to 800 mm.
9. The structural body of claim 1 , wherein the plastic element is attached to the structural component with mechanical fixing measures.
10. The structural body of claim 1 , wherein the structural component is a floor rocker.
11. The structural body of claim 1 , wherein the structural component is a bumper beam.
12. The structural body of claim 1 , wherein the structural component has a space having a major axis, and wherein the honeycomb structure comprises channels, and wherein the channels are oriented perpendicular to the major axis.
13. The structural body of claim 1 , wherein the plastic element is inseparably attached to the metal support.
14. The structural body of claim 1 , wherein at least one of the walls of the metal support has grooves and holes through the walls in the grooves.
15. The structural body of claim 14 , wherein plastic from the plastic element is located through the holes and in the grooves.
16. A vehicle, comprising:
a structural body comprising:
a hollow structural component comprising walls that define a component channel, wherein the structural component has a component length, and wherein the structural component is selected from the group consisting of beam, rail, pillar, chassis, floor rocker, and cross-bar, combinations comprising at least one of the foregoing; and
a reinforcement comprising a plastic element having a honeycomb structure, and a metal support having greater than or equal to 3 walls forming a support channel;
wherein the plastic element is located in the support channel; and
wherein the reinforcement is located in the component channel;
an engine; and
a drive mechanism.
17. The vehicle of claim 16 , wherein the structural component has a space having a major axis, and wherein the honeycomb structure comprises channels, and wherein the channels are oriented perpendicular to the major axis.
18. A reinforcement configured for insertion into a structural component of a vehicle, comprising:
a plastic element having a honeycomb structure, and
a metal support having greater than or equal to 3 walls forming a support channel;
wherein at least one of the walls of the metal support has grooves and holes through the walls in the grooves;
wherein plastic from the plastic element extends through the holes and into the grooves;
wherein the plastic element is located in the support channel and is inseparably attached to the metal support.
19. The reinforcement of claim 18 , wherein the plastic fills the grooves forming a flat outer surface.