WO2023136993A1 - Structure sandwich en matériau composite pour composants de véhicule - Google Patents

Structure sandwich en matériau composite pour composants de véhicule Download PDF

Info

Publication number
WO2023136993A1
WO2023136993A1 PCT/US2023/010372 US2023010372W WO2023136993A1 WO 2023136993 A1 WO2023136993 A1 WO 2023136993A1 US 2023010372 W US2023010372 W US 2023010372W WO 2023136993 A1 WO2023136993 A1 WO 2023136993A1
Authority
WO
WIPO (PCT)
Prior art keywords
composite sandwich
vehicle cargo
sandwich panel
panel material
construct
Prior art date
Application number
PCT/US2023/010372
Other languages
English (en)
Inventor
Hugh FORAN
Matt PLAUMAN
Evan FREEMAN-GIBB
Patrick DURHAM
Original Assignee
Teijin Automotive Technologies, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Teijin Automotive Technologies, Inc. filed Critical Teijin Automotive Technologies, Inc.
Publication of WO2023136993A1 publication Critical patent/WO2023136993A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/04—Superstructures, understructures, or sub-units thereof, characterised by the material thereof predominantly of synthetic material
    • B62D29/043—Superstructures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D33/00—Superstructures for load-carrying vehicles
    • B62D33/02—Platforms; Open load compartments
    • B62D33/023—Sideboard or tailgate structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/10—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
    • B32B2255/102—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer synthetic resin or rubber layer being a foamed layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/101—Glass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/107—Ceramic
    • B32B2264/108—Carbon, e.g. graphite particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0221—Vinyl resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0221—Vinyl resin
    • B32B2266/0228—Aromatic vinyl resin, e.g. styrenic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0221—Vinyl resin
    • B32B2266/0235—Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/025—Polyolefin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0264—Polyester
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0278—Polyurethane
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/08—Closed cell foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/406—Bright, glossy, shiny surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54—Yield strength; Tensile strength
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/546—Flexural strength; Flexion stiffness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B32B2307/737—Dimensions, e.g. volume or area
    • B32B2307/7375—Linear, e.g. length, distance or width
    • B32B2307/7376—Thickness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels

Definitions

  • the present invention in general relates to composite materials and in particular to a composite sandwich structure for forming vehicle components including cargo beds and pickup truck boxes, roofs, hoods, liftgates, and doors.
  • Composite materials are materials made from two or more constituent materials with significantly different physical or chemical properties, that when combined, produce a material with characteristics different from the individual components. The individual components remain separate and distinct within the finished structure.
  • a composite material may be preferred for many reasons: common examples include materials which are stronger, lighter, or less expensive when compared to traditional materials.
  • a sandwich- structured composite is a special class of composite material that is fabricated by attaching two thin but stiff skins to a lightweight but thick core. The core material is normally a low strength material, but its higher thickness provides the sandwich composite with high bending stiffness with overall low density.
  • Still another problem conventional to the art is that structure edges are ineffective and allow for infiltration of humidity or moisture that becomes entrained within the core and often inconsistent with finished vehicle surface requirements. With temperature extremes this entrained moisture can reduce the operational lifetime of the structure, while increasing the weight thereof.
  • These problems of moisture infiltration are particularly pronounced in instances when the core is formed of cellulosic materials such as paper. Attempts have been made to provide a core material that is formed of a plastic material instead of paper, but such materials have proven to be too expensive and complex to manufacture for such purposes.
  • truck beds and walls defining cargo compartments 100 are integrally formed as part of the vehicle body 102, which is then fastened to the vehicle frame 104.
  • some typical truck beds and walls defining cargo compartments 100 are integrally formed with the vehicle frame 104 structure, separate from the body of the cab portion 106 of the vehicle.
  • typical truck beds and walls defining cargo compartments are formed of steel, in order to withstand the typical wear and tear exerted upon truck beds and walls defining cargo compartments.
  • truck beds and walls defining cargo compartments In order to reduce the weight of components associated with truck beds and walls defining cargo compartments, attempts have been made to form truck beds and walls defining cargo compartments out of aluminum; however, such truck beds and walls defining cargo compartments are easily punctured by objects placed in the cargo compartments during ordinary use. To avoid such punctures, other scratches, or damage to the truck bed and walls defining cargo compartments resulting from usual pickup truck use, users typically install a robust polymeric liner within the cargo compartment to cover the steel or aluminum truck bed and walls defining cargo compartments. Such truck bed liners are an added expense to consumers, add to the weight of the vehicle, and reduce the usable space available within the cargo compartment.
  • the present invention provides a vehicle cargo construct that includes a floor having an upper surface and an oppositely opposed lower surface, a plurality of side wall panels extending from the floor, and an end wall panel extending from the floor between the plurality of side wall panels.
  • Each of the plurality of side wall panels and end wall panel having an exterior surface and an oppositely opposed interior surface.
  • Each of the floor, the plurality of side wall panels, and the end wall panel being formed of a composite sandwich panel material that includes a core defining a plurality of pores, a surface sheet adhered to a first face of the core by a first adhesive layer, and a structural skin adhered to a second face of the core by a second adhesive layer.
  • FIG. 1 is a schematic drawing showing a side view of a typical pickup truck in which the cargo compartment is integrally formed with the vehicle body;
  • FIG. 2 is a schematic drawing showing a side view of a typical pickup truck in which the cargo compartment is integrally formed with the vehicle frame;
  • FIG. 3 shows an exploded perspective view of an inventive vehicle cargo construct according to embodiments of the present invention
  • FIG. 4 is a partial cutaway, perspective view of a composite sandwich panel material used to form embodiments of the inventive cargo construct
  • FIG. 5 is an enlarged partial cutaway, side view of the composite sandwich panel material of FIG. 4 along a line bisecting the hexagonal pores;
  • FIGS. 6A-6D are cross-sectional views of edges of a composite sandwich panel material
  • FIG. 7 is a partial cutaway, perspective view of a composite sandwich panel material having a conduit used to form embodiments of the inventive component construct
  • FIG. 8 is a cross sectional view of a hard point at which a vehicle cargo construct is attached to a vehicle frame or chassis according to embodiments of the present disclosure
  • FIG. 9 is a partial cutaway, perspective view of a composite sandwich panel material used to form embodiments of the inventive cargo construct
  • FIG. 10 is an enlarged partial cutaway, side view of the composite sandwich panel material of FIG. 9;
  • FIG. 11 is a partial cutaway, perspective view of a composite sandwich panel material having a conduit used to form embodiments of the inventive component construct
  • FIG. 12 shows a perspective view of an inventive roof assembly formed with an inventive composite sandwich structure according to embodiments of the present invention
  • FIG. 13 shows a perspective view of an inventive hood assembly formed with an inventive composite sandwich structure according to embodiments of the present invention
  • FIG. 14 shows a perspective view of an inventive liftgate assembly formed with an inventive composite sandwich structure according to embodiments of the present invention
  • FIG. 15 shows a cross sectional view of an inventive unitary vehicle cargo construct according to embodiments of the present invention.
  • FIG. 16A shows a crosscar cross sectional view of a vehicle cargo construct according to embodiments of the present invention
  • FIG. 16B shows a front to back cross sectional view of the vehicle cargo construct of FIG. 16A
  • FIG. 17A shows a crosscar cross sectional view of a vehicle cargo construct according to embodiments of the present invention
  • FIG. 17B shows a front to back cross sectional view of the vehicle cargo construct of FIG. 17A;
  • FIG. 18A shows a crosscar cross sectional view of a vehicle cargo construct according to embodiments of the present invention
  • FIG. 18B shows a front to back cross sectional view of the vehicle cargo construct of FIG. 18 A;
  • FIG. 19A shows a crosscar cross sectional view of a vehicle cargo construct according to embodiments of the present invention.
  • FIG. 19B shows a front to back cross sectional view of the vehicle cargo construct of FIG. 19A
  • FIG. 20 is a graph showing maximum payloads versus deflection
  • FIG. 21 is a graph showing maximum pay load versus weight of an 8 foot pickup box
  • FIG. 22 is a graph showing maximum payload versus investment cost.
  • the present invention has utility as a composite sandwich panel structure 10 with a core 12 sandwiched between a high gloss surface sheet 14 and a structural skin 16 that are adhered to the core so as to reduce delamination of the formed part.
  • the composite sandwich panel structure 10 is well suited for forming vehicle components including vehicle cargo bed and pickup truck boxes, roofs, doors, hoods, and liftgates, as shown in FIGS. 3 and 12-14 and described in further detailed in U.S. Patent Application No. 17/420,160, U.S. Patent Application No. 17/618,176, and U.S. Patent Application No. 17/618,139, the contents of which are hereby incorporated by reference.
  • the high gloss surface sheet 14 is readily formed with a mold platen that confers a surface texture simulative wood grain, or other surface that is both decorative and provides additional friction upon contacting the surface. Such surfaces being particularly favored in the floor of a pick-up truck bed liner.
  • the sheet 14 is replaced with another structural skin 16 (not shown) so as to create a sandwich between two opposing structural skins 16 that join at the edges to isolate the core 12 from the exterior.
  • the composition from which the sheet 14 or skin 16 is formed includes an ultraviolet light stabilizer.
  • Suitable UV absorbing additives include for example, hydroxybenzophenones; hydroxybenzotriazoles; hydroxybenzotriazines; cyanoacrylates; oxanilides; benzoxazinones; 2- (2H-benzotriazol-2-yl)-4-(l,l,3,3-tetramethylbutyl)-phenol (CYASORBTM 5411); 2-hydroxy-4- n-octyloxybenzophenone (CYASORBTM 531); 2-[4,6-bis(2,4-dimethylphenyl)-l,3,5-triazin-2- yl]-5-(octyloxy)-phenol (CYASORBTM 1164); 2,2'-(l,4-phenylene)bis(4H-3,l-benzoxazin-4-one) (CYASORBTM UV-3638); l,3-bis[(2-cyano-3,3-diphenylacryloyl)oxy]-2,2-bis[
  • the present invention has utility as a light weight yet robust vehicle cargo bed and pickup truck box formed with a composite core sandwich structure capable of withstanding typical wear and tear and environmental elements experienced by truck cargo compartments.
  • the use of the composite sandwich structure allows for replacement of traditional materials such as steel or aluminum, without a loss of strength, in a vehicle’s cargo bed or pickup truck box while also reducing the overall weight of the vehicle.
  • the present invention has utility as components for forming a cargo bed or pickup truck box structure having a high gloss surface suitable for the vehicle exterior and having an opposite robust surface suitable for lining a truck cargo compartment, while being a high strength and light weight vehicle component.
  • the sandwich composite structure provides a high gloss surface sheet and structural skin that are adhered to the core with an adhesive or glue that is viscous when applied.
  • the viscosity of the adhesive as applied allows for contact with the interior volume of the core to create more adhesion surface area yet without excessively running into the pores defined in the core before the adhesive cured or hardens thereby providing greater adhered contact area between the components of the sandwich composite structure.
  • reduced delamination of the components of the sandwich composite structure is observed as well as precluding bond line readthrough into the high gloss surface sheet.
  • Embodiments of the present invention also have utility as watertight and waterproof composite sandwich panel structures.
  • the term “high gloss surface” refers to a surface having minimal perceptible surface defects when visually inspected for about three seconds from about 24-28 inches from the viewer and normal to the part surface +/- 90 degrees in a well-lit area. That is, the term “high gloss surface” refers to a surface capable of being painted and accepted as a “Class A” autobody part. This is commonly measured by ASTM D523. In the automotive industry, a Class A surface is a surface a consumer can see without functioning the vehicle (e.g., opening the hood or decklid), while a Class A surface finish generally refers to painted outer panels and specifically to the distinctness of image (DOI) and gloss level on the part. It is appreciated that a surface layer may be subjected to sanding, trimming, and priming prior to receiving a paint coating that imparts high gloss, yet must retain dimensionality and adhesion uniformity to primer and paint so as to achieve a high gloss finish.
  • DOI distinctness of image
  • FIG. 3 shows an exploded perspective view of an inventive vehicle cargo construct 50 according to embodiments of the present invention.
  • the vehicle cargo construct 50 includes a floor 52, a plurality of side wall panels 58 extending from said floor 52, and an end wall panel extending 64 from said floor 52 between the side wall panels 58.
  • the floor 52 has an upper surface 54 and an oppositely opposed lower surface 56.
  • Each of the side wall panels 58 has an exterior surface 60 and an oppositely opposed interior surface 62.
  • the end wall panel 64 has an exterior surface 66 and an oppositely opposed interior surface 68.
  • the floor 52, the side wall panels 58, and the end wall panel 64 are formed of a composite sandwich panel material 10, such as that shown in FIGS. 4-11.
  • the composite sandwich panel material 10 includes a core 12.
  • the core 12 is a pre-cut piece of a polymeric foam material.
  • the polymeric foam in some inventive embodiments is a closed-cell foam. Typical foam hardness values range from J to B on the pencil hardness scale.
  • Suitable polymers from which such foam material is formed illustratively include polyurethane, polyurea, ethyl-vinyl acetate, polypropylene, polyethylene, polystyrene, polycarbonate, polyvinyl chloride, polylactic acid, silicone, polycarbonate, microcellular material, and combinations thereof.
  • the core 12 terminates in faces 17 and 17’, a surface sheet 14 adhered to a first face 17 of the core 12 by a first adhesive layer 20, and a structural skin 16 adhered to a second face 17’ of the core 12 by a second adhesive layer 22.
  • FIGS. 4 and 9 show enlarged cross-sectional views of a composite sandwich panel material 10 used to form the inventive cargo construct 50 according to embodiments of the invention.
  • FIGS. 5 and 10 show further details of the various layers making up the composite sandwich panel material 10.
  • a cloth 19 is present intermediate between the face 17 of the core 12 and the surface sheet 14, the cloth 19 being embedded within the adhesive 20.
  • the structural skin 16 is adhered to an opposing second side of the core 12 by a second adhesive layer 22.
  • a cloth 19’ is present intermediate between the face 17’ of core 12 and the structural skin 16, the cloth 19’ being embedded within the adhesive 22.
  • the core 12 is formed of a lightweight material that defines a plurality of pores 24 so as to reduce the overall density of the core 12.
  • the core 12 is formed from a variety of materials that include cellulosics such as corrugated fiberboard, paper board, paper stock; thermoplastics such as poly(methyl methacrylate) (PMMA), acrylonitrile butadiene styrene (ABS), polyamides, polylactides, polybenzimidazoles, polycarbonates, polyether sulfones, polyethylene, polypropylene, polystyrene, polyvinyl chloride, and block copolymers of any one of the aforementioned where at least one of the aforementioned makes up the majority by weight of the copolymer and regardless of the tacticity of the polymer or copolymer; thermosets such as polyesters, polyureas, polyurethanes, polyurea/polyurethanes, epoxies, vinyl esters; metal such as
  • the core 12 is formed of an open area core 12 having a plurality of walls 26 that define pores 24 arranged in a patterned array.
  • the core 12 is formed of a foam having a plurality of pores 24.
  • the foam may be an open-cell foam or a closed-cell foam.
  • the adhesive layers 20, 22 are formed of either a thermoplastic or curable formulation, a polyurethane or polyurethane prepolymer adhesive, which may be in the form of glue, a moisture cure adhesive, a reactive hot melt adhesive, or a polyurethane resin. As shown in FIGS. 5 and 10, due to the compressive force applied to the adhesive layers 20, 22 between the surface sheet 14 and the core 12 and the structural skin 16 and the core 12, the adhesive 20, 22 is engineered to have an initial viscosity on contact with the face 17 so as partially fill the pores 24 of the core 12. The viscosity of the adhesive layers 20, 22 ensures that the adhesive does not excessively run into the pores defined in the core before the adhesive attains final strength.
  • the adhesive surface area for adhesion between a surface sheet and structural skin and the core is at least 5% more than the surface area of the face.
  • This increased surface area of adhesion reduces delamination of the components of the composite sandwich 10 and surprisingly allows for the use of thinner surface sheets that do not exhibit bond line read through.
  • As a result of increasing the adhesive surface area coverage from 10 to 50 surface areas percent allows for the comparatively expensive high gloss surface sheet to be reduced in thickness from 1.5 mm to between 1.3 and 0.8 mm while still preventing of bond line read through.
  • the surface sheet 14 of the composite sandwich panel 10 is formed from sheet molding compound (SMC), thermoplastic, dicyclopentadiene (DCPD), overmolded polyurethane (PU), or a combination thereof.
  • the surface sheet 14 is a high gloss surface sheet having a high gloss surface 15.
  • the surface sheet 14 can include a filler material 30 to reinforce and/or serve to decrease the weight of the high gloss surface sheet 14.
  • the filler material 30 is any of glass fibers, carbon fibers, natural fibers, hollow or solid glass microspheres, or a combination thereof.
  • the filler material is present in an amount of 45 to 65 % of the surface sheet material.
  • the fibers may be oriented or non-oriented.
  • a resin package sold by Continental Structural Plastics, Inc. under the tradenames TCA® and TCA® ULTRA-LITETM are used herein. Exemplary formulations of which are detailed in U.S. 7,700,670; WO2017/184761; and U.S. 7,524,547B2. It is appreciated that the high gloss sheet routinely includes additives to retain dimensionality. Such additives routinely including glass fiber; carbon fiber; inorganic particulate fillers such as calcium carbonate, talc, and carbon black; glass microspheres; carbon nanotubes; graphene; low profile additives; moisture scavengers; and combinations thereof.
  • additives routinely including glass fiber; carbon fiber; inorganic particulate fillers such as calcium carbonate, talc, and carbon black; glass microspheres; carbon nanotubes; graphene; low profile additives; moisture scavengers; and combinations thereof.
  • Typical thicknesses of the high gloss surface sheet in the present invention range from 0.5 to 5 millimeters (mm) without regard to edges.
  • the surface sheet 14 has a flexural modulus of 8.6 to 14.6 GPa.
  • the surface sheet 14 has a tensile modulus of 11 to 19.4 GPa.
  • the surface sheet 14 has a flexural strength of 261 to 368 MPa.
  • the surface sheet 14 has a tensile strength of 150 to 287 MPa.
  • the high gloss surface sheet tends to be a comparatively dense component and an expensive portion to manufacture given the materials used and necessary forming processes to maintain minimal perceptible surface defects suitable for a Class A autobody part.
  • the high gloss surface sheet 14 tends to deform when supported by limited portions of the face 17 above the core 12. While resort to a large contact surface area of the first adhesive layer 20 is advantageous, in some inventive embodiments a cloth 19 is embedded in the first adhesive layer 20.
  • the structural skin 16 is adhered to the second side of the core 12 by the second adhesive layer 22.
  • the structural skin 16 is formed of a fiber mat having non-oriented, non-woven fibers, unidirectional, or woven fibers, a thermoplastic sheet, or an SMC.
  • the structural skin 16 provides a robust and durable surface. In some embodiments, the structural skin 16 terminates against the backside of the surface sheet 14 to encapsulate the core 12.
  • the composite sandwich panel material 10 provides sound damping, fire retardancy, thermal insulation, or a combination thereof by use of a foam core 12 and/or by placing a sound and/or heat absorbing material within the pores 24 of the core 12.
  • the pores 24 of the core 12 are at least partially filled with a fill 49.
  • the fill illustratively including foam pellets, fire retardant, or a phase change material.
  • Phase change materials operative herein include waxes or an inorganic salt hydrates.
  • the surface sheet 14 and the structural skin 16 are joined together along an edge 33A- 33D of the composite sandwich panel material 10 to form a seal, as shown in FIGS. 6A-6D, respectively.
  • the core 12 is fully enclosed and moisture is inhibited from entering the interior of the composite sandwich panel assembly 10.
  • the components of the inventive cargo construct 50 formed of the composite sandwich panel assembly 10 are exposed to natural elements including sun, snow, humidity, and rain, preventing moisture from entering the interior of the composite sandwich panel material 10 is important given that freeze thaw cycles of moisture within the part cause expansion and potentially failure of the composite sandwich panel material
  • the core 12 is formed of a polymeric foam, according to embodiments, moisture penetration into the interior of the sandwich structure 10 is less of a concern as compared to embodiments where the core 12 is formed of a hydrophilic material such as paper.
  • FIGS. 6A-6D show various embodiments of ways in which the surface sheet 14 and the structural skin 16 are joined together to form a sealed edge 33A-33D, respectively according to the present disclosure.
  • an elastomeric gasket 34 is disposed between the surface sheet 14 and the structural skin 16 at the 33C to make the edge 33C more water resistant. It is appreciated that a gasket is readily included in the other edge joinder 33A, 33B, and 33D. The gasket 35 enhances maintenance of the edge seal over a wider range of use conditions.
  • At least one of the surface sheet 14 and the structural skin 16 requires enough material to wrap around the edge of the composite sandwich 10.
  • at least one of the surface sheet 14 and the structural skin 16 is provided in dimensions greater than the dimensions of the final composite part such that the material is able to wrap around the final edge composite sandwich 10.
  • the at least one of the surface sheet 14 and the structural skin 16 is preformed such that it has edges extending generally perpendicularly from the plane of the sheet material.
  • excess material is cut from the composite sandwich once the edge seal is formed.
  • excess material of the structural skin 16 has been trimmed from the composite sandwich assembly 10 by a knife or router that presses against the divot 35A that is formed by the surface sheet 14.
  • FIG. 6B the edge 33B formed by removing excess material for tool engagement against a shoulder 35B of the surface sheet 14.
  • FIG. 6C the edge 33C formed by removing excess material for tool engagement against a shoulder 35C of the surface sheet 14.
  • excess material of one or both the surface sheet 14 and the structural skin 16 are trimmed with tool pressure against shoulder 35D.
  • embodiments of an inventive vehicle cargo construct 50 include a conduit system 120 embedded within the composite sandwich panel material 10 of the vehicle component.
  • the conduit system 120 is embedded in the core 12 of composite sandwich panel assembly 10 that forms the vehicle cargo construct 50.
  • the conduit system 120 comprises tubing or wires that are molded into the core 12 of the composite sandwich 10 before the vehicle component is formed.
  • the conduit system 120 includes electrical wiring, ventilation ducts, or heating elements. Accordingly, embodiments of the inventive vehicle cargo construct 50 are capable of including features such as speakers, lights, air vents, and defrosting elements for removing ice or snow present on the vehicle cargo construct 50.
  • the conduit systems 120 of various vehicle components are configured to align with one another to form a single connected conduit system throughout the vehicle to connect electrical wiring, ventilation ducts, and/or heating elements of each of an inventive vehicle cargo construct with like electrical wiring, ventilation ducts, and/or heating elements of the vehicle to function.
  • the floor 52, the side wall panels 58, and the end wall panel 64 of the vehicle cargo construct 50 are integrally formed of a single piece of composite sandwich panel material 10 or each piece is formed of a separate piece of composite sandwich panel material 10.
  • the vehicle cargo construct 50 is a single unitary construct that is configured to be attached to a vehicle, as shown in FIG. 15.
  • the vehicle cargo construct 50 is formed a several separate pieces that are configured to be joined together and to a vehicle frame, as shown in FIG. 3.
  • the cargo construct 50 is formed by folding the side walls 58 and the end wall 64 up from the plane of the floor 54.
  • the folding includes crushing portions of the composite sandwich panel material 10, particularly the core 12 along the fold lines.
  • the floor 52, the side wall panels 58, and/or the end wall panel 64 of the vehicle cargo construct 50 include a plurality of hard points 90, as shown in FIG. 8.
  • the hard points 90 are configured to be points at which the vehicle cargo construct 50 is attached to the vehicle frame or chassis 91.
  • the hard points 90 are through holes defined in the composite sandwich panel material 10 that forms the vehicle cargo construct 50.
  • a fastener such as a bolt 94, is inserted through the hard point 90 and through an opening defined in the vehicle frame 91, securing the vehicle cargo construct 50 to the vehicle frame 91 using a nut 96.
  • the hard points 90 are formed in mounting recesses 93 that are formed in the structural skin surface of the composite sandwich panel material 10, thus allowing the head of the fastener 94 to be recessed into the mounting recess 93 so that the head of the fastener 94 is flush with the surface of the cargo compartment that is defined by the structural skin 16 of the composite sandwich panel material 10.
  • the hard points 90 include a collar 92 disposed within the through hole that forms the hard point 90. The collar 92 may be inserted into the through hole defined by the composite sandwich panel material 10 after the through hole is formed in the composite sandwich panel material 10 or the collar 92 may be pre -positioned and the composite sandwich panel material 10 formed around the collars 92.
  • the lower surface 56 of the floor 52 is defined by the surface sheet 14 of the composite sandwich panel material 10 and the oppositely opposed upper surface 54 of said floor 52 is defined by the structural skin 16 of the composite sandwich panel material 10.
  • the exterior surface 60 of each of the side wall panels 58 is defined by the surface sheet 14 of the composite sandwich panel material 10 and the oppositely opposed interior surface 62 of each of the side wall panels 58 is defined by the structural skin 16 of the composite sandwich panel material 10.
  • the exterior surface 66 of the end wall panel 64 is defined by the surface sheet 14 of the composite sandwich panel material 10 and the oppositely opposed interior surface 68 of the end wall panel 64 is defined by the structural skin 16 of the composite sandwich panel material 10.
  • surface sheet 14 of the composite sandwich panel material 10 is a high gloss surface sheet with a high gloss finish 15 with minimal perceptible surface defects suitable for a Class A autobody part. Accordingly, in some embodiments the exterior surface 60 of each of the side wall panels 58 is a high gloss surface sheet 14.
  • the upper surface 54 of the floor 52, the interior surface 62 of each of the side walls 58, and the interior surface 68 of the end wall 64 define a cargo compartment within the vehicle cargo construct 50. Given that these surfaces are defined by the structural skin 16 of the composite sandwich panel 10, these surfaces that define the cargo compartment are high strength, robust, and resistant to scratches, punctures, and other damage.
  • the vehicle cargo construct 50 additionally includes a second end wall panel 70 extending from the floor 52 between the side wall panels 58.
  • the second end wall panel 70 is formed a separate piece of the composite sandwich panel 10.
  • the second end wall panel 70 has an exterior surface 72 and an oppositely opposed interior surface 74.
  • the exterior surface 72 of the second end wall panel 70 is defined by the surface sheet 14 of the composite sandwich panel material 10 and the oppositely opposed interior surface 74 of the second end wall panel 70 is defined by the structural skin 16 of the composite sandwich panel material 10.
  • the surface sheet 14 has a high gloss surface 15, thus the exterior surface 72 of the second end wall panel 70 has a finish that is suitable for a vehicle exterior.
  • the second end wall panel 70 is a tailgate attached to the floor 52 by a hinge.
  • the second end wall panel 70 is configured to pivot about the hinge to open and close the end of the containment construct 50, thereby allowing a user access to the cargo compartment within the vehicle cargo construct 50 when the tailgate 70 is in its open position, and enclosing the cargo compartment within the vehicle cargo construct 50 when the tailgate 70 is in its closed position.
  • any of the side wall panels 58 and/or the end wall panels, 64, 70 are formed of a double wall of composite sandwich panel material 10.
  • a void may be formed between the two walls of composite sandwich panel material 10.
  • the compartment may have a locking door formed in either one or both of the surrounding walls of composite sandwich panel material 10. Accordingly, items such as tools may be securely stored within the vehicle cargo construct 50.
  • the vehicle cargo construct 50 additionally includes a plurality of wheel wells 76 each having an interior surface 78 and an exterior surface 80.
  • Each of the wheel wells 76 configured to receive a wheel of the vehicle on the side of the exterior surface 80 of the wheel well 76 and partially surround the wheel of the vehicle.
  • the plurality of wheel wells 76 are defined by and are integrally formed with each of the side wall panels 58.
  • the wheel wells 76 are structures formed separately from the side wall panels 58.
  • Each of the wheel wells 76 is positioned between one of the side wall panels 58 and the floor 52.
  • the vehicle cargo construct 50 additionally includes a plurality of cap sections 82 positioned along an upper edge of any or all of the side wall panels 58, the end wall panel 64, and the second end wall panel 70.
  • the cap sections 82 are formed of the composite sandwich panel material 10.
  • the cap section 82 may be integrally formed with the panel from which it extends or may be formed of a separate piece of composite sandwich material 10 that is then attached to the corresponding panel to form the vehicle cargo construct 50.
  • the vehicle cargo construct 50 additionally includes a plurality of shoulders 83.
  • the shoulders 83 are configured to join and/or cover the corner edges of the wall sections 58, 64.
  • the shoulders 83 may be positioned within the cargo construct or may be on the exterior side of the cargo construct 50.
  • the vehicle cargo construct 50 additionally includes a c-shaped outer frame positioned along the edges of the floor 52 and walls 58, 64. The c-shaped outer frame provides increased rigidity at the edges to further strengthen the cargo construct 50.
  • embodiments of the vehicle cargo construct 50 include a bed liner 84 positioned on the upper surface 54 of the floor 52 of the containment construct 50.
  • the bed liner 50 is formed of the composite sandwich panel material 10.
  • the bed liner 84 is removable from the cargo construct 50 such that the bed liner 84 may be removed, easily washed, or replaced.
  • the vehicle cargo construct 50 includes a plurality of break lines 88 or corrugations formed in the floor 52, the side wall panels 58, the end wall panels 64, 70, the cap sections 82, the be liner 84, the wheel wells 76, or a combination thereof.
  • break lines 88 provide a predetermined crumple path in the event of an impact so that the composite sandwich panel material 10 of each part crumples and absorbs impact energy.
  • the break lines 88 are formed by crushing or pre-cutting the core 12 of the composite sandwich panel material 10 in pre-determined locations.
  • the vehicle cargo construct of the present invention is capable of supporting light, medium and heavy duty pay loads. That is, a light and medium duty pickup box pay load is typically between 773 and 1408 kg, while a medium to heavy duty pickup box payload is typically between 762 and 1976 kg.
  • the present invention is capable of supporting these pay loads.
  • Embodiments of the inventive vehicle cargo construct provide numerous benefits including providing a grain or pattern on the floor of the pickup box, the ability to provide molded in features such as pockets and support boards, UV stability without the use of pain, resistance to corrosion and chemicals, weight reduction of about 20-30% overall, no visible spot welds or seams, resistance to impacts, dents, and scratches, no need to use an additional bed liner (which results in a savings for the consumer), ease of cleaning, a covered D-pillar so there is no exposed metal material that could otherwise rust, reduced insurance claim repair costs given that repairs require less time and expense, improved assembly tolerance from about +/-6mm to +/-2 mm crosscar, reduced tooling costs for manufacturers, and higher resale value and long term appearance.
  • FIGS. 16A-19B show various cross sectional view of an inventive vehicle cargo construct according to various embodiments of the present invention. [0077] FIGS. 16A and 16B show an embodiment of a light to medium duty cargo construct.
  • the cargo construct shown is formed of a single wall SMC construction and includes molded in ribs and features in the floor channels for added stiffness. This is a seamless box that mounts to a vehicle frame. Such a construction is configured to support up to 907 kg of payload while only weighing 41.7 kg itself.
  • FIGS. 17A and 17B show an embodiment of a light to medium duty cargo construct.
  • the cargo construct shown is formed of a single wall SMC construction and includes floor channels for added stiffness. This is a seamless box.
  • the construct includes underbox steel roll formed reinforcements that mount to the frame of the vehicle. An additional steel reinforcement may be used to support upper regions of the SMC box.
  • Such a construction is configured to support up to 1497 kg of payload while only weighing 45.4 kg itself.
  • FIGS. 18A and 18B show an embodiment of a heavy duty cargo construct.
  • the cargo construct shown is formed of a single wall SMC construction and includes floor channels for added stiffness. This is a seamless box.
  • the construct includes underbox steel roll formed reinforcements that mount to the frame of the vehicle. Such a construction is configured to support up to 1996 kg of payload while only weighing 46 to 52 kg itself.
  • FIGS. 19A-19B show an embodiment of a heavy duty cargo construct.
  • the cargo construct shown is formed of a double wall SMC construction bonded to a core material such as a high density PVC foam.
  • the construct includes molded in ribs, features, and floor channels for added stiffness. This is a seamless box.
  • Such a construction is configured to support up to 1996 kg of pay load while only weighing 99.1 kg itself.
  • Patent documents and publications mentioned in the specification are indicative of the levels of those skilled in the art to which the invention pertains. These documents and publications are incorporated herein by reference to the same extent as if each individual document or publication was specifically and individually incorporated herein by reference.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Mechanical Engineering (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention concerne une construction de cargaison de véhicule comprenant un plancher ayant une surface supérieure et une surface inférieure opposée, une pluralité de panneaux de paroi latérale s'étendant à partir du plancher et un panneau de paroi d'extrémité s'étendant à partir du plancher entre la pluralité de panneaux de paroi latérale. Chacun de la pluralité de panneaux de paroi latérale et du panneau de paroi d'extrémité ont une surface extérieure et une surface intérieure opposée. Chacun du plancher, de la pluralité de panneaux de paroi latérale et du panneau de paroi d'extrémité sont formés d'un matériau de panneau en sandwich composite constitué d'un noyau à surface ouverte définissant une pluralité de pores, d'une feuille de surface collée à une première face du noyau par une première couche adhésive et d'une peau structurale collée à une seconde face du noyau par une seconde couche adhésive.
PCT/US2023/010372 2022-01-11 2023-01-09 Structure sandwich en matériau composite pour composants de véhicule WO2023136993A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US202263298363P 2022-01-11 2022-01-11
US63/298,363 2022-01-11

Publications (1)

Publication Number Publication Date
WO2023136993A1 true WO2023136993A1 (fr) 2023-07-20

Family

ID=87279593

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2023/010372 WO2023136993A1 (fr) 2022-01-11 2023-01-09 Structure sandwich en matériau composite pour composants de véhicule

Country Status (1)

Country Link
WO (1) WO2023136993A1 (fr)

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6176537B1 (en) * 1998-07-31 2001-01-23 Durakon Industries, Inc. Charge dissipating bed liner
US20080174149A1 (en) * 2007-01-18 2008-07-24 Simms Adrian R Structural insulation panel
US20140130657A1 (en) * 2012-11-05 2014-05-15 Gordon Holdings, Inc. High strength, light weight composite structure, method of manufacture and use thereof
WO2015164353A1 (fr) * 2014-04-22 2015-10-29 Celltech Metals Inc. Structure multicouche comprenant une feuille extérieure rainurée
WO2021146518A1 (fr) * 2020-01-15 2021-07-22 Continental Structural Plastics, Inc. Construction de compartiment de chargement de véhicule en matériau composite

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6176537B1 (en) * 1998-07-31 2001-01-23 Durakon Industries, Inc. Charge dissipating bed liner
US20080174149A1 (en) * 2007-01-18 2008-07-24 Simms Adrian R Structural insulation panel
US20140130657A1 (en) * 2012-11-05 2014-05-15 Gordon Holdings, Inc. High strength, light weight composite structure, method of manufacture and use thereof
WO2015164353A1 (fr) * 2014-04-22 2015-10-29 Celltech Metals Inc. Structure multicouche comprenant une feuille extérieure rainurée
WO2021146518A1 (fr) * 2020-01-15 2021-07-22 Continental Structural Plastics, Inc. Construction de compartiment de chargement de véhicule en matériau composite

Similar Documents

Publication Publication Date Title
US10793201B1 (en) Pickup truck cargo box subassembly
US11865905B2 (en) Multi-panel removable roof
US20230166798A1 (en) Composite material modular utility vehicle construct
US20150360734A1 (en) Truck Body Assembly and Methods of Making and Using Same
US11628650B2 (en) Open area core sandwich structure assembly with vehicle exterior surface glass
US20230046294A1 (en) Composite material vehicle cargo compartment construct
US20230057344A1 (en) Composite material vehicle cargo compartment construct
JPH0826148A (ja) 自動車の外装材
US20220234427A1 (en) Composite material vehicle component construct
WO2023136993A1 (fr) Structure sandwich en matériau composite pour composants de véhicule
US20220242086A1 (en) Composite material vehicle component construct
CN112638756B (zh) 皮卡车货箱子组件
KR101940115B1 (ko) 코어 메티리얼을 포함하는 열경화성 소재를 적용한 썬루프 판넬
US20230158784A1 (en) Vehicle component unit and method for producing a vehicle component unit
US20230415466A1 (en) Open area core sandwich structure manufacturing tool

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 23740589

Country of ref document: EP

Kind code of ref document: A1