Composite material with insert-molded attachment steel

Abstract

A composite material with an insert-molded attachment steel is provided. The composite material includes a plurality of burring apertures, each of which has a flange in one direction on the attachment steel and is inserted between fibers. A resin is then introduced between the fibers in each burring aperture and external to the flange.

Claims

1. A composite material, comprising: a first fiber layer and a second fiber layer; an attachment steel comprising at least one embedded portion positioned between the first and second fiber layers and a corresponding attachment portion extending therefrom and not positioned between the first and second fiber layers; the embedded portion comprising a plurality of burring apertures each having a peripheral flange extending a height from a surface of the attachment steel toward the first or second fiber layer; and a resin introduced between the first and second fiber layers, the resin surrounding the at least one embedded portion, extending into the burring apertures and around the peripheral flanges; wherein the resin extending into each of the burring aperture forms a shear strength reinforcing portion between the first and second fiber layers and the attachment steel, a thickness of the shear strength reinforcing portion defined as the distance between the first and second fiber layers, wherein the thickness of the shear strength reinforcing portion is greater than the height of the peripheral flange.

2. The composite material of claim 1, wherein the peripheral flange is formed along an entire periphery of each burring aperture and extends perpendicular to the surface of the attachment steel.

3. The composite material of claim 1, wherein each burring aperture is formed as a circular aperture.

4. The composite material of claim 1, wherein the resin extending around each of the peripheral flanges forms a further shear strength reinforcing portion, a thickness of the further shear strength reinforcing portion defined as the distance between the surface of the attachment steel and the first fiber layer or the second fiber layer the peripheral flange extends toward.

5. The composite material of claim 4, wherein the thickness shear strength reinforcing portion is greater than the thickness of the further shear strength reinforcing portion.

6. The composite material of claim 5, wherein the thickness shear strength reinforcing portion is greater than a thickness between the first and second fiber layers at a location of the embedded portion not having a burring aperture.

7. The composite material of claim 6, wherein the thickness of the further shear strength reinforcing portion is graduated as it transitions from the shear strength reinforcing portion to locations of the embedded portion not having a burring aperture.

8. The composite material of claim 1, where the fibers are carbon fibers or aramid fibers.

9. The composite material of claim 1, wherein the corresponding attachment portion comprises a welded end.

10. The composite material of claim 9, wherein the at least one embedded portion comprises a first embedded portion and its corresponding attachment portion comprises a first welded end, the first welded end being welded to a vehicle body component.

11. The composite material of claim 10, further comprising a second embedded portion and its corresponding attachment portion is bent at an angle relative to the first welded end and comprises a second welded end, the second welded end also being welded to the vehicle body component.

12. A method of forming the composite material of claim 1, comprising: forming the plurality of burring apertures in at least one portion of the attachment steel; positioning the at least one portion between the first and second fiber layers, the at least one portion having the corresponding attachment portion extending therefrom and not positioned between the first and second fiber layers; and introducing the resin between the first and second fiber layers via insert molding, the resin surrounding the at least one portion, extending into the burring apertures and around the peripheral flanges, forming the at least one embedded portion.

13. The method of claim 12 further comprising: forming the peripheral flange along an entire periphery of each burring aperture; and forming the peripheral flange as extending perpendicular from the surface of the attachment steel.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The above and other features of the present invention will now be described in detail with reference to exemplary embodiments thereof illustrated the accompanying drawings which are given hereinbelow by way of illustration only, and thus are not limitative of the present invention, and wherein:

(2) FIG. 1 is an exemplary cross-sectional view of a composite material with an insert-molded attachment steel according to an exemplary embodiment of the present invention; and

(3) FIG. 2 is an exemplary cross-sectional view of the composite material with the insert-molded attachment steel according to the exemplary embodiment of the present invention.

DESCRIPTION OF SYMBOLS

(4) 1: Vehicle body component 10: Attachment steel 11: Flange 13: Burring aperture 15: Welded end 20: Fiber 30: Resin 40: Shear strength reinforcing portion

DETAILED DESCRIPTION

(5) Hereinafter, an exemplary embodiment of the present invention will be described with reference to the accompanying drawings. However, the drawings illustrated below and the following description relate to one exemplary embodiment among various exemplary embodiments for effectively explaining features of the present invention. While the invention will be described in conjunction with exemplary embodiments, it will be understood that present description is not intended to limit the invention to those exemplary embodiments. On the contrary, the invention is intended to cover not only the exemplary embodiments, but also various alternatives, modifications, equivalents and other exemplary embodiments, which may be included within the spirit and scope of the invention as defined by the appended claims.

(6) The terminology used herein is for the purpose of describing particular exemplary embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms a, an and the are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms comprises and/or comprising, when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term and/or includes any and all combinations of one or more of the associated listed items. For example, in order to make the description of the present invention clear, unrelated parts are not shown and, the thicknesses of layers and regions are exaggerated for clarity. Further, when it is stated that a layer is on another layer or substrate, the layer may be directly on another layer or substrate or a third layer may be disposed therebetween.

(7) It is understood that the term vehicle or vehicular or other similar term as used herein is inclusive of motor vehicle in general such as passenger automobiles including sports utility vehicles (SUV), buses, trucks, various commercial vehicles, watercraft including a variety of boats, ships, aircraft, and the like and includes hybrid vehicles, electric vehicles, combustion, plug-in hybrid electric vehicles, hydrogen-powered vehicles and other alternative fuel vehicles (e.g. fuels derived from resources other than petroleum).

(8) FIG. 1 is an exemplary cross-sectional view of a composite material with an insert-molded attachment steel according to an exemplary embodiment of the present invention. FIG. 2 is an exemplary cross-sectional view of the composite material with the insert-molded attachment steel according to the exemplary embodiment of the present invention. Referring to FIGS. 1 and 2, the composite material with the insert-molded attachment steel (hereinafter, referred to as the composite material) according to the exemplary embodiment of the present invention may be applied to securely attach a vehicle body component 1 via an insert-molded attachment steel 10.

(9) The composite material may include a plurality of burring apertures 13 having flanges 11 in one direction on the attachment steel 10. In particular, the flange 11 may be formed in one direction along a circumference of the burring aperture 13 and may be formed in a direction perpendicular to a cross section of the attachment steel 10. In the exemplary embodiment of the present invention, the flange 11 may be formed in the direction perpendicular to the cross section of the attachment steel 10, but the present invention is not necessarily limited thereto, and a direction and an angle of the flange 11 may be adjusted. Further, the burring aperture 13 may be formed as a circular aperture.

(10) Further, resin 30 may be introduced into fibers 20 when the attachment steel 10 is formed between the fibers 20 by insert-molding. In particular, two layers of fibers 20 according to the exemplary embodiment of the present invention are illustrated for convenience as an example, but the present invention is not necessarily limited thereto and various layers may be formed to overlap each other. A shear strength reinforcing portions 40 may be formed between the fibers 20 when the resin 30 is introduced in the burring aperture 13 and external to the flange 11.

(11) The shear strength reinforcing portion 40 may improve shear strength between the fibers 20 and the attachment steel 10. At least a portion of the shear strength reinforcing portion 40 may have a thickness greater than a thickness of the composite material and a height of the flange 11. In other words, a thickness t of the composite material may vary based on a thickness of the shear strength reinforcing portion 40. The thickness of the shear strength reinforcing portion 40 may vary based on a height of the burring aperture 13.

(12) The composite material configured as described above may be formed from fiber reinforced plastic (FRP). The fiber reinforced plastic may refer to a composite material that may be reinforced by using glass fibers as a reinforcing material and impregnating the resin. Additionally, the fiber reinforced plastic may be lightweight and may have excellent formability. In particular, the fiber reinforced plastic may be applied as a lightweight material with an increased strength and improved elasticity by using a new material that may include a carbon fiber, an aramid fiber, and a reinforcing fiber or the like, as a reinforcing material. Further, welded ends 15 may be formed along an exterior tip which is not insert-molded between the attachment steel 10 and the fibers 20. The welded end 15 may couple the vehicle body component 1 to the composite material and one side tip portion thereof may be bent.

(13) FIG. 1 illustrates that the two attachment steels 10 may be formed by insert-molding to couple the composite material to the vehicle body component 1 and to form the two welded ends 15. In other words, a first welded end 15 may be formed at a portion where the attachment steel 10 extends toward the vehicle body component 1, and a second welded end 15 may be formed at a portion where the attachment steel 10 extends and is bent. The number of attachment steels 10 and the number of welded ends 15 may be determined by a shape of the vehicle body component 1 intended to be coupled to the composite material. In particular, the attachment steel 10 may be coupled by welding W to the vehicle body component 1 along the welded ends 15 at the exterior tip and the attachment strength may be improved.

(14) Therefore, the composite material with the insert-molded attachment steel 10 according to the exemplary embodiment of the present invention may improve shear strength between the attachment steel 10 and the composite material. In particular, the resin 30 may be introduced when the attachment steel 10 formed with the plurality of burring apertures 13 having the flange 11 in one direction that may be formed by insert-molding between the fibers 20. Further, the composite material with the insert-molded attachment steel 10 may improve attachment strength even though the thickness of the attachment steel 10 is not increased by the shear strength reinforcing portion 40 formed by the burring aperture 13. The attachment steel 10 may be coupled by welding W, to the vehicle body component 1 through the welded ends 15 at the exterior tip and may improve the attachment strength.

(15) While this invention has been described in connection with what is presently considered to be exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.