Hybrid reinforcement structure
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.
1. A structural reinforcement comprising:
i) an elongated base reinforcing portion having a longitudinal axis;
ii) an expandable polymeric material at least partially associated with the elongated base reinforcing portion; and
iii) a localized reinforcement aligned generally parallel with the longitudinal axis and located within a contemplated impact deformation region of the structural reinforcement wherein the localized reinforcement is made of a metallic material that is dissimilar from and has a higher tensile strength than a material of the elongated base reinforcing portion so that upon impact in the impact deformation region, severity of deformation is reduced as compared to a part without the localized reinforcement;
wherein the localized reinforcement includes a fastener to attach the localized reinforcement to a component selected from a 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; and
wherein the elongated base reinforcing portion is molded over and around the localized reinforcement.
2. 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.
3. The structural reinforcement of claim 1 , wherein the localized reinforcement is substantially completely covered by the elongated base reinforcing portion, the expandable material, or both.
4. The structural reinforcement of claim 1 , wherein the elongated base reinforcing portion includes a curved first surface that is in contact with a curved localized reinforcement.
5. The structural reinforcement of claim 1 , wherein the localized reinforcement is a composite material.
6. 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.
7. The structural reinforcement of claim 4 , 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.
8. The structural reinforcement of claim 1 , wherein the expandable polymeric material has a ductility ratio of about 2.5.
9. The structural reinforcement of claim 1 , wherein the localized reinforcement has a generally curved or U-shaped profile.
10. The structural reinforcement of claim 2 , wherein the ductility of the elongated base reinforcing portion material is less than the ductility of the localized reinforcement material.
11. The structural reinforcement of claim 2 , wherein the localized reinforcement has one or more visible exposed surfaces after expansion of the expandable polymeric material.
12. The structural reinforcement of claim 10 , 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.