Granted Patent B2

US 12,208,550 · App. 17/243,862 · Granted Jan 28, 2025

Inventors: Thomas Baranowski (Wurselen, DE); Maik Broda (Wurselen, DE); Markus Franzen (Stolberg, DE); Pascal Rebmann (Weilerswist, DE)

Assignee: Ford Global Technologies, LLC

B29C45/0053B29C44/42B29C45/0001B29C2045/0079B29K2033/26B29L2031/3008

Abstract

Claims (29)

1. A method for producing a dashboard support for a motor vehicle, the method comprising the steps of:

producing an elongate core from a foam material;

at least partially surrounding the elongate core with a unidirectional layer to form a reinforced elongate core, wherein the unidirectional layer comprises a unidirectional fiber-reinforced tape which has fibers embedded in a polymer and oriented parallel to one another and in one direction;

arranging fastening structures along a length of the reinforced elongate core between first and second ends of the reinforced core; and

overmolding the reinforced elongate core and the fastening structures with a thermoplastic material to couple the fastening structures with the reinforced elongate core.

2. The method according to claim 1 , further comprising the step of layering the tape around the core.

3. The method according to claim 1 , further comprising the step of winding the tape around the core.

4. The method according to claim 1 , further comprising the step of adhesively bonding the unidirectional layer to the core.

5. The method according to claim 1 , wherein the foam material for the core is a polymethacrylimide.

6. The method according to claim 1 , wherein the step of producing the core comprises producing the core by injection molding.

7. A method for producing a dashboard support for a motor vehicle, the method comprising the steps of:

producing an elongate core from a foam material by injection molding;

at least partially surrounding the elongate core with a unidirectional layer to form a reinforced elongate core, wherein the unidirectional layer comprises a unidirectional fiber-reinforced tape which has fibers embedded in a polymer and oriented parallel to one another and in one direction;

inserting the reinforced elongate core into a secondary mold;

arranging fastening structures on a length of the reinforced elongate core between first and second ends of the reinforced elongate core; and

overmolding to secure the fastening structures onto the reinforced elongate core.

8. The method according to claim 7 , further comprising the step of layering the tape around the core.

9. The method according to claim 7 , further comprising the step of winding the tape around the core.

10. The method according to claim 7 , further comprising the step of adhesively bonding the unidirectional layer to the core.

11. The method according to claim 7 , wherein the foam material for the core is a polymethacrylimide.

12. A dashboard support for a motor vehicle, the support comprising:

a core made of a foam material via injection molding;

a unidirectional layer at least partially surrounding the core to form a reinforced core, wherein the unidirectional layer comprises a unidirectional fiber-reinforced tape which has fibers embedded in a polymer and oriented parallel to one another and in one direction; and

at least one fastening structure inserted partially within the core during the injection molding and coupled with a body of the reinforced core via overmolding of a thermoplastic material.

13. The method according to claim 7 , further comprising:

inserting the foam material into a primary mold to form the elongate core via the injection molding.

14. The dashboard support according to claim 12 , wherein the at least one fastening structure comprises at least one of a clamp, a clip and an insert.

15. The method according to claim 7 , wherein the at least one fastening structure comprises at least one of a clamp, a clip and an insert.

16. The method according to claim 1 , wherein the at least one fastening structure comprises at least one of a clamp, a clip and an insert.

Assignments (1)

Priority Claims (1)

Continuity (1)

References Cited (17)