Abstract
The present invention relates to a reinforcement member made from a polymeric material. The present invention further relates to a vehicle comprising the reinforcement member, a method to absorb an impact on vehicle and a method to produce the reinforcement member.
Claims
1: A reinforcement member, comprising a multitude of reinforcement elements, each element comprising a plate and a layer of a multitude of hollow cells, wherein the reinforcement elements are interconnected by a material bond and/or by a form- and/or force-fit.
2: The reinforcement member according to claim 1, wherein the hollow cells are honeycombs.
3: The reinforcement member according to one claim 1, wherein one end of the hollow cells of one reinforcement element are connected to the bottom of the plate of an adjacent reinforcement element.
4: The reinforcement member according to claim 1, wherein it is asymmetrical relative to one center plane.
5: The reinforcement member according to claim 1, wherein it comprises along its main extension direction different zones.
6: A vehicle including a structure, wherein a hollow cell of the structure is reinforced by the reinforcement member according to claim 1.
7: The vehicle according to claim 6, wherein the longitudinal extension direction of the hollow cell is parallel to the reinforcement direction or impact direction.
8: A vehicle according to claim 6, wherein the cross-section of the reinforced structure comprises an indentation.
9: A vehicle according to claim 6, wherein the hollow cell surrounds at least partially a battery case.
10: A method to absorb an impact of a vehicle on a vehicle according to claim 6, wherein the reinforcement member rotates and/or twists during the impact.
11: The method according to claim 10, wherein the reinforcement member is deformed plastically.
12: A method to produce a reinforcement member according to claim 1, wherein that the reinforcement elements (1) are glued or welded together and/or connected by a force- and/or form-fit.
13: The method according to claim 12, wherein, a layer of hollow cells are connected to a plate.
14: The reinforcement member of claim 1, wherein a second reinforcement member is located adjacent the reinforcement member and also includes a multitude of hollow cells.
15: The reinforcement member of claim 14, where in the multitude of hollow cells of the second reinforcement member are arranged in a direction so that they lie perpendicular to the multitude of hollow cells of the reinforcement member.
16: The reinforcement member of claim 15, wherein the reinforcement member and second reinforcement member are aligned adjacent a battery case.
17. The reinforcement member of claim 1, wherein each layer of multitude of hollow cells is arranged in a direction that is perpendicular to the direction of the multitude of hollow cells of any adjacent layer.
18: The reinforcement member of claim 1, wherein each layer of multitude of hollow cells is arranged in a direction that is perpendicular to the direction of at least one other layer of multitude of hollow cells.
19: The reinforcement member of claim 4, wherein each layer of multitude of hollow cells is arranged in a direction that is perpendicular to the direction of at least one other layer of multitude of hollow cells.
20: The reinforcement member of claim 14, wherein each layer of multitude of hollow cells is arranged in a direction that is perpendicular to the direction of at least one other layer of multitude of hollow cells.
Description
[0030] In the following the inventions are explained according to the figures. These explanations do not limit the scope of protection. The explanations apply to all embodiments of the present invention likewise.
[0031] FIG. 1 shows an embodiment of a reinforcement element.
[0032] FIGS. 2-3b show different views of a reinforcement member.
[0033] FIG. 4 depicts the method to produce the inventive reinforcement member.
[0034] FIG. 5a-d shows the vehicle in a side impact situation.
[0035] FIG. 6 shows an asymmetrical reinforcement member.
[0036] FIGS. 7-10 show a reinforcement member with different segments.
[0037] FIGS. 11-12 show special embodiment of the reinforcement member.
[0038] FIG. 1 shows an embodiment of the reinforcement element 1. In the present case this element comprises a plate 2, that extends over the entire length and widths of the reinforcement element 1. Directly adjacent and connected to the plate is a layer 3 of hollow cells, in the present case a honeycomb structure 17. Each cell of layer 3 has a longitudinal extension direction 18, which is delimited by two ends. One of those ends is connected to plate 2, for example by a material bond and/or a form- and/or form-fit. One end 19 of the layer 3 of hollow cells will be connected to the plate 2 of an adjacent reinforcement element 1 as shown below in further detail. The longitudinal extension 18 of the layer 3 is preferably 10-50 mm. The thickness of plate 2 is preferably 0.5-3 mm. The sidewall thickness of the cells is preferably between 1 and 5 mm and the inner diameter, the hollow diameter of the cells, is preferably between 4 and 15 mm. The skilled person understands that instead of a honeycomb structure, the cells 17 can be a pipe with a circular- or polygon-cross section. An elliptic cross section is also an option.
[0039] FIGS. 2-3b show an embodiment of a reinforcement member 4. In the present case, the reinforcement member 4 comprises 6 reinforcement elements 1. As can particularly be seen from FIG. 2, one end of the layer 3 of hollow cells is connected to the plate 2 of an adjacent reinforcement element. In the present case, the reinforcement elements are connected by an adhesive layer 16, which is, in the present case, applied only locally. In FIG. 2 the preferred impact direction 6 is also depicted. Preferably, the plates 2 extend perpendicular to the impact direction 6, while the main extension direction 18 of the hollow cells 3 is parallel to the impact direction.
[0040] Preferably, a layer 3 of hollow cells is the first layer, that faces the impact 6, while the reinforcement member 4 is on the opposite side delimited by a plate 2. Reference is now made to FIG. 3a, in which the main extension 5 of the reinforcement member 4 can be seen. The plate 2 and the layer 3 of hollow cells preferably extend over the entire main extension 5. Preferably, the same is true for the widths 22 of the reinforcement member 4. Particularly in FIG. 3b, it can be seen, that the adhesive between two adjacent reinforcement element 1 is carried out by, in the present case three, adhesive layers. The skilled person understands, that there can also be more or less adhesive layers and that the adhesive layer can also extend over the entire widths 22 and length 5 of the reinforcement member 4. From all FIGS. 2-3b it can be seen, that the impact 6 first hits a layer 3 of hollow cells.
[0041] The assembly process of the reinforcement member 4 is explained according to FIG. 4. At first standard semi-finished products are provided which each comprise a plate 2 and a layer 3 of hollow cells. The plate 2 and the layer 3 can be provided as one single part, for example by moulding. The plate 2 and the layer 3 can also be, as depicted, assembled to provide the semi-finished part 1. The connection between the plate and the layer 3 can be a material bond and/or a form- and/or force-fit. In the present case, the surface opposite from the layer 3 is provided with an adhesive layer 16, in the present case a continuous adhesive layer 16. In the next step, the individual reinforcement elements 1, in the present case six elements, are connected by pressing the adhesion layer 16 against the free end 19 of the layer 3 of hollow cells.
[0042] The connection between the reinforcement elements 1, regardless how it is executed, is preferably such, that it does not delaminate during an impact. The same is true for the connection between the plate and the layer 3 of hollow cells.
[0043] FIGS. 5a-5d show the inventive reinforcement member 4 assembled in the structure 7 of a vehicle. In the present case the structure 7 is a beam, as can be particularly seen in FIG. 5d.
[0044] According to this example, the reinforcement member 4 comprises three connected reinforcement elements 1. As can be particularly seen in FIG. 5a, the sidewall 11 of the structure 7 comprises an indentation 8 at which the left-hand side plate 2 of the reinforcement member 4 is not in contact with the sidewall 11. The consequences of a side crash can be seen particularly according to FIGS. 5a-5c. In the embodiment according to FIG. 5a the structure 7 and the reinforcement member 4 are in their original state. In FIG. 5b, the side impact 6 starts to compress the structure 7 and hence, the reinforcement member 4. Due to the indentation 8 in the sidewall 11 of the structure 7, the reinforcement member 4 is not only compressed but twisted locally, which is depicted by arrow 9. This twisting, but also the entire deformation of the reinforcement member 4, dissipates so much energy, that the battery case 10, which is relative to the impact 6 behind the structure 7 including the reinforcement member 4 is not deformed at all, so that batteries, which are stored in the case are well protected. This can be seen from FIG. 5c which shows the final state at the end of an impact. In FIG. 5d, the final state after the impact 6 is also depicted. It can be seen, that the reinforcement member 4 is deformed locally but that the battery case is fully intact.
[0045] FIG. 6 shows an alternative embodiment of the reinforcement member 4. In the present case, the reinforcement member 4 is asymmetrical relative to one of its center planes 21, in the present case, the center plane 21 that is parallel to the impact direction 6. The asymmetry is in the present case due to an inclined surface 12. This embodiment of the reinforcement member 4 is particularly advantages for embodiments in which the sidewall 11 of the structure 7 is straight and does not have an indentation 8 as shown in FIG. 5. Due to the asymmetry during an impact, the reinforcement member 4 also twists as explained according to FIG. 5 and hence shows an improved energy absorption.
[0046] FIGS. 7-10 show a preferred embodiment of the inventive reinforcement member. In the present case, this reinforcement member 4 comprises three sections 13-15. These sections can differ in terms of material as well as in terms of the reinforcement elements 1 and/or their orientation. The section 13 is preferably designed to absorb a front crash, while the section 14 is preferably designed to absorb a side crash and the section 15 is preferably designed to improve the stiffness of the rear of a vehicle for example during lifting of the vehicle for repair. The common coordinate system X-Z used in automotive applications is depicted in FIG. 7. In FIG. 7 also preferred load applications as well as preferred martials are listed. In FIGS. 8-10 a preferred embodiment of the reinforcement member according to FIG. 7 is depicted. FIG. 9 shows a section of the middle segment 14 as well as of the rear segment 15. The middle section 14 is the reinforcement member already explained previously, for example according to FIGS. 2 and 3. In the segment 15, in the present case four reinforcement elements 1 are connected. The plates 2 of these reinforcement elements extend in the present case in a horizontal plane while the longitudinal extension direction 18 of the hollow cells of layer 3 extends vertically. Due to this arrangement particularly forces in Z-direction can be absorbed. In FIG. 10, the segment 13 and the segment 14 are depicted. Regarding segment 14 reference is made to the above-said. Segment 13 is designed to absorb a front crash. Consequently, the longitudinal extension direction 18 of the hollow cells are directed in X-direction and the plates 2 perpendicular to the X-direction to absorb a load in X-direction.
[0047] FIG. 11 shows a specific embodiment of the inventive reinforcement element. In the present case, the reinforcement elements 1 are not identical. Starting from the left-hand side the second and the fifth layer differ from the rest, because the orientation of the longitudinal extension direction of the cells is different in comparison to the first, third, fourth and sixth layer. In layers two and five the longitudinal extension direction is rotated by 90° so that this axis is in present case parallel to the main extension direction 5 of the reinforcement member 4. Due to this design, this reinforcement member 4 can absorb impacts into different directions, for example aside and a front impact. The skilled person understands, that the orientation, the shape, the size and/or the length of layer 3 can differ from reinforcement element to reinforcement element.
[0048] FIG. 12 shows an embodiment in which the plate 2 is not a continuous solid part, but also comprises hollow structures.
REFERENCE SIGNS
[0049] 1 reinforcement element [0050] 2 plate [0051] 3 layer of hollow cells [0052] 4 reinforcement member [0053] 5 main extension of the reinforcement member 4 [0054] 6 reinforcement direction, impact direction, side impact [0055] 7 structure, structure of a vehicle beam, cavity [0056] 8 rotation means, indentation [0057] 9 rotation [0058] 10 battery case [0059] 11 sidewall of the structure, sidewall of the cavity [0060] 12 rotation means, inclined surface at the reinforcement member [0061] 13 front segment of a reinforcement member [0062] 14 middle-segment of a reinforcement member [0063] 15 rear segment of a reinforcement member [0064] 16 connection layer, adhesive layer [0065] 17 hollow structure, cells [0066] 18 longitudinal extension direction [0067] 19 one end of the structure [0068] 20 bottom of the plate [0069] 21 center plane [0070] 22 width of the reinforcement member 4 [0071] X longitudinal direction of a vehicle, front to rear extension [0072] Y transverse direction [0073] Z vertical direction
