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US 2019/0270230 A1Published application
Water-assisted injection molded cross-car beam
AssigneeFord Global Technologies, LLC
InventorsDan Busuioc, Bernard Gerard Marchetti, Gary D. Mullen, Nicholas Andrew Mazzocchi
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Abstract
A method of forming a cross-car beam is provided. A composite is melted to form a viscous polymer. The polymer is injected into a mold. Pressurized fluid is injected into the mold to evacuate a portion of the viscous polymer from the mold and to form a channel therethrough. The remaining viscous polymer is cooled within the mold to form a cross-car beam.
Claims20
A method of forming a cross-car beam, comprising the steps of:
- melting a composite material to form a viscous polymer;
- injecting the viscous polymer into a mold;
- injecting a pressurized fluid into the mold to evacuate a portion of the viscous polymer from the mold and to form a channel therethrough;
- and
- cooling the remaining viscous polymer within the mold to form a cross-car beam.
2 more elements
The method of forming a cross-car beam, comprising the steps of:
- melting a composite material to form a viscous polymer;
- injecting the viscous polymer into a mold, the mold comprising a cavity that remains unfilled with viscous polymer;
- injecting a pressurized fluid into the mold in order to force a portion of viscous polymer into the cavity to form a channel enclosed by a layer of solid composite material;
- and
- cooling the viscous polymer within the mold to form a cross-car beam.
2 more elements
A cross-car beam assembly, comprising;
- a composite beam structure comprised of carbon fibers within a nylon resin;
- a channel disposed within the composite beam structure formed by:
- injecting a viscous polymer into a cross-car beam mold;
- inserting a pressurized fluid into the mold as the viscous polymer begins to cool such that a portion of viscous polymer is displaced from the mold;
- cooling the remaining viscous polymer within the mold to form a cross-car beam.
2 more elements
Dependencies are inferred from the claim text.