IP Library › Granted Patent US 12,240,215
Granted Patent B2
US 12,240,215 · App. 17/719,761 · Granted Mar 4, 2025

Hybrid reinforcement structure

Inventors: Henry E. Richardson (Washington, MI); Xuping Qian (Novi, MI); Gary Hulett (Memphis, MI)
Assignee: ZEPHYROS, INC.
B32B7/022B29C65/4855B32B3/04B32B3/28B32B7/02B32B7/08B32B9/041B32B15/08B62D29/002B32B2305/08B32B2605/00
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Quick Facts
Patent No.
US 12,240,215
App. No.
17/719,761
Granted
Mar 4, 2025
Kind
B2
Abstract

A structural reinforcement for insertion into a cavity of a vehicle structure including a base reinforcing portion, an expandable material and a localized reinforcement is disclosed. The localized reinforcement is placed within the structural reinforcement at a location of anticipated increased deformation during vehicle impact in an effort to reduce deformation and control the load distribution post-impact.

Claims (26)

1. A structural reinforcement for insertion into a cavity of an automotive vehicle, the structural reinforcement comprising:

i) an elongated base reinforcing portion having:

a) a longitudinal axis,

b) a network of ribs, and

c) notches formed in opposing walls of the elongated base reinforcing portion;

ii) an expandable polymeric material located at least partially on the elongated base reinforcing portion; and

iii) a localized reinforcement aligned generally parallel with the longitudinal axis and located within the notches of the elongated base reinforcing portion; and

wherein the ductility of the elongated base reinforcing portion is less than the ductility of the localized reinforcement.

2. The structural reinforcement of claim 1 , wherein the localized reinforcement includes a fastening means that fastens the localized reinforcement to a vehicle structure or to the base reinforcing portion.

3. The structural reinforcement of claim 2 , wherein the fastening means attaches to any mounting bracket, a seat belt mechanism or retractor, a pull handle bracket, a roof rack, a mirror bracket, a sunroof bracket, a bumper bracket, a hinge component, a chassis mount bracket, an engine bracket, a suspension component, or a radiator bracket.

4. The structural reinforcement of claim 1 , wherein the localized reinforcement is made of a metallic material selected from steel, aluminum, titanium, nickel, magnesium, an alloy, a transition metal, or any combination thereof.

5. The structural reinforcement of claim 1 , wherein the localized reinforcement is made of polyurethanes, polyurethane composites, or any combination thereof.

6. The structural reinforcement of claim 1 , wherein the localized reinforcement is substantially covered by the elongated base reinforcing portion, the expandable polymeric material, or both.

7. The structural reinforcement of claim 1 , wherein the localized reinforcement is a composite material.

8. The structural reinforcement of claim 1 , wherein the localized reinforcement has an outer surface and at least a portion of the outer surface is in contact with the expandable polymeric material after expansion.

9. The structural reinforcement of claim 1 , wherein the expandable polymeric material has a ductility ratio of about 2.5.

10. The structural reinforcement of claim 1 , wherein the localized reinforcement has a generally curved or U-shaped profile.

11. The structural reinforcement of claim 1 , wherein the elongated base reinforcing portion is a metal part, a composite part, a polymeric part, or any combination thereof.

12. The structural reinforcement of claim 1 , wherein the localized reinforcement has one or more visible exposed surfaces after expansion of the expandable polymeric material.

13. The structural reinforcement of claim 1 , wherein the structural reinforcement includes a top portion, a middle portion, and a bottom portion so that the localized reinforcement is only in contact with the middle portion.

14. The structural reinforcement of claim 1 , wherein the expandable polymeric material is an epoxy-based material.

15. The structural reinforcement of claim 1 , wherein the localized reinforcement is made of a material that is dissimilar from and has a higher tensile strength than the material of the elongated base reinforcing portion so that upon impact in an impact deformation region, a severity of deformation is reduced as compared to a part without the localized reinforcement.

16. The structural reinforcement of claim 1 , wherein the network of ribs is disposed outward from the localized reinforcement.

17. The structural reinforcement of claim 1 , wherein the network of ribs is disposed over the localized reinforcement.

18. The structural reinforcement of claim 1 , wherein the notches extend partially into the opposing walls of the elongated base reinforcing portion.

19. The structural reinforcement of claim 1 , wherein the notches extend continuously along the longitudinal axis of the elongated base reinforcing portion.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jun 8, 2022
From: RICHARDSON, HENRY E.; QIAN, XUPING; HULETT, GARY
To: ZEPHYROS, INC.
Reel/Frame 060131/0629 →
Continuity (8)
Continuation 16587733 · Sep 30, 2019
Continuation 15727237 · Oct 6, 2017
Continuation 14874521 · Oct 5, 2015
Continuation 14269262 · May 5, 2014
Continuation 13866448 · Apr 19, 2013
Continuation 12613862 · Nov 6, 2009
Provisional Application 61112331 · Nov 7, 2008
Related Publication 20220242091A1 · Aug 4, 2022
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