Composite tubular door beam reinforced with a reacted core localized at the mid-span of the tube
AssigneeMPA Diversified Products Inc.
InventorJoseph S. Wycech
Life of this patent
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Abstract
A lightweight, composite beam with a reacted core for reinforcing a vehicle door is provided. The reinforcing beam comprises a metal tube having a longitudinal cavity which is partially filled with either a reinforcing polymeric core which in one aspect includes a thermoset or thermoplastic resin-based material or a cementitious core which includes Portland cement and a filler. The reacted core is friction fit or mechanically held within the metal tube at the mid-span of the tube. The composite beam includes end pieces which are adapted to be mounted to a vehicle door panel in a door cavity by spot-welds or the like. The horizontally mounted beam provides substantially increased resistance to side impacts to the vehicle door in the event of a collision.
Claims29
A lightweight, composite reinforcing door beam adapted to be mounted in the cavity of a motor vehicle door which has an outer panel and an inner panel, the door beam providing structural reinforcement in the form of increased side-impact resistance when mounted in the cavity of the vehicle door, the door beam comprising:
- a metal tube having a longitudinal axis and having a bore coextensive therewith:
- a reacted core disposed in said bore of said metal tube, said core occupying not more than one-third of the length of said bore:
- said core being positioned substantially at the mid-span of said metal tube:
- said core being held in place in said bore of said tube:
- first and second mounting means disposed at opposite ends of said body and adapted for mounting the door beam in the cavity of the vehicle door, with the longitudinal axis of the door beam positioned horizontally with respect to the vehicle door, thereby increasing the side-impact resistance of the vehicle door;
- and
- said reacted core being selected from a group consisting of synthetic resin and Portland cement.
A lightweight, composite reinforcing door beam adapted to be mounted in the cavity of a motor vehicle door which has an outer panel and an inner panel, the door beam providing structural reinforcement in the form of increased side-impact resistance when mounted in the cavity of the vehicle door, the door beam comprising:
- a metal tube having a longitudinal axis and having a bore coextensive therewith;
- a reacted core disposed in said bore of said metal tube, said core occupying not more than one-third of the length of said bore;
- said core being positioned substantially at the mid-span of said metal tube;
- said core being held in place in said bore of said tube;
- first and second mounting means disposed at opposite ends of said body and adapted for mounting the door beam in the cavity of the vehicle door, with the longitudinal axis of the door beam positioned horizontally with the respect to the vehicle door, thereby increasing the side-impact resistance of the vehicle door;
- and
- said reacted core comprising about 100 parts by weight Portland cement and about 0.3% to 2.0% by weight of cement of the thermoplastic microspheres.
A lightweight, composite reinforcing door beam adapted to be mounted in the cavity of a motor vehicle door which has an outer panel and an inner panel, the door beam providing structural reinforcement in the form of increased side-impact resistance when mounted in the cavity of the vehicle door, the door beam comprising:
- a metal tube having a longitudinal axis and having a bore coextensive therewith;
- a reacted core disposed in said bore of said metal tube, said core occupying not more than one-third of the length of said bore;
- said core being positioned substantially at the mid-span of said metal tube;
- said core being held in place in said bore of said tube;
- first and second mounting means disposed at opposite ends of said body and adapted for mounting the door beam in the cavity of the vehicle door, with the longitudinal axis of the door beam positioned horizontally with respect to the vehicle door, thereby increasing the side-impact resistance of the vehicle door;
- and
- said reacted core comprising generally equal volumes of Portland cement and thermoplastic microspheres.
A lightweight, composite reinforcing door beam adapted to be mounted in the cavity of a motor vehicle door which has an outer pamel and an inner panel, the door beam providing structural reinforcement in the form of increased side-impact resistance when mounted in the cavity of the vehicle door, the door beam comprising:
- a metal tube haivng a longitudinal axis and having a bore coextensive therewith:
- a reacted core disposed in said bore of said metal tube, said core occupying not more than one-third of the length of said bore:
- said core being positioned substantially at the mid-span of said metal tube;
- said core being held in place in said bore of said tube;
- first and second mounting means disposed at opposite ends of said body and adapted for mounting the door beam in the cavity of the vehicle door, with the longitudinal axis of the door beam positioned horizontally with respect to the vehicle door, thereby increasing the side-impact resistance of the vehicle door;
- and
- said reacted core comprising Portland cement and a filler, in generally equal volumes.
A reinforced vehicle door comprising:
- an inner door panel and an outer door panel joined to define a door cavity;
- a lightweight, composite door beam within said door cavity;
- said door beam having a longitudinal metal tube that defines a bore;
- an inorganic cementitious core disposed in said bore, said core occupying no more than one-third of the length of said bore;
- said core being positioned substantially at the mid-span of said metal tube;
- said core being held in place in said bore of said tube;
- and
- first and second mounting means disposed at opposite ends of said metal tube for mounting said door beam in said cavity of said vehicle door.
A method of forming an impact beam comprising the following steps:
- (a) providing a metal tube defining a bore;
- (b) providing an inorganic cementitious core adapted to be received within said metal tube, said cementitious core having a length not greater than one-third the length of said metal tube;
- and
- (c) sliding said cementitious core into said bore of said metal tube such that said core occupies the mid-span of said metal tube.
A composite structural article for use in vehicles comprising:
- a hollow metal component having a longitudinal axis;
- and
- an inorganic cementitious core disposed in the interior of said metal component, and located therein in the area of high stress concentration;
- said cementitious core being heold in place in the interior of said component.
Dependencies are inferred from the claim text.