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US 6,821,638 B2Granted
Shaped contoured crushable structural members and methods for making the same
AssigneeDelphi Technologies, Inc.
InventorDale Francis Obeshaw
Life of this patent
Estimating the term…
Abstract
Shaped, contoured crushable structural members and methods for making the same are described. The contoured structural members comprise composite or metal materials sandwiching a support or stabilizing structure. The structural members are made crushable by incorporating an initiator into the structural members. The structural member crushes at the location of the initiator by absorbing the energy of an exerting load. The shaped structure is provided by bending the generally straight shape of the structural member. With a shaped, contoured, crushable, and generally non-flat structure, applications and uses for the structural members of the present invention are nearly limitless.
Claims39
A shaped contoured structural member, comprising:
- an inner section containing a continuous plurality of contoured layers comprising a composite material or a metal-containing material;
- an outer section containing a continuous plurality of contoured layers comprising a composite material or a metal-containing material;
- and
- at least one intermediate layer having a honeycomb core structure connecting the inner section and the outer section.
1 more element
A structural member having a substantially non-straight longitudinal shape, comprising:
- an inner section containing a continuous plurality of contoured layers comprising a composite material or a metal-containing material;
- an outer section containing a continuous plurality of contoured layers comprising a composite material or a metal-containing material;
- and
- at least one intermediate layer having a ribbed structure connecting the inner section and the outer section.
1 more element
A bent structural member, comprising:
- an inner section containing a continuous plurality of contoured layers comprising a composite material or a metal-containing material;
- an outer section containing a continuous plurality of contoured layers comprising a composite material or a metal-containing material;
- and
- at least one intermediate layer having a honeycomb structure connecting the inner section and the outer section.
1 more element
A method for making a shaped, contoured structural member, comprising:
- providing an inner section containing a continuous plurality of contoured layers comprising a composite material or a metal-containing material over a shaped mandrel;
- roll wrapping at least one intermediate layer over the inner section, the at least one intermediate layer having a honeycomb core structure;
- providing an outer section over the at least one intermediate layer, the outer section containing a continuous plurality of contoured layers comprising a composite material or a metal-containing material;
- and
- connecting the inner and outer sections to the at least one intermediate layer.
2 more elements
A method for making a shaped, contoured structural member, comprising:
- providing an inner section containing a continuous plurality of contoured layers comprising a composite material or a metal-containing material over a substantially straight mandrel;
- roll wrapping at least one intermediate layer over the inner section, the at least one intermediate layer having a ribbed structure;
- providing an outer section over the at least one intermediate layer, the outer section containing a continuous plurality of contoured layers comprising a composite material or a metal-containing material;
- removing the mandrel;
- modifying the shape of the inner section, at least one intermediate layer, and the outer section to a substantially non-straight shape;
- and
- connecting the inner and outer sections to the at least one intermediate layer.
4 more elements
A method for making a shaped, contoured structural member, comprising:
- providing an inner section containing a continuous plurality of contoured layers comprising a composite material or a metal-containing material over a shaped mandrel;
- roll wrapping at least one intermediate layer over the inner section, the at least one intermediate layer having a ribbed structure;
- providing an outer section over the at least one intermediate layer, the outer section containing a continuous plurality of contoured layers comprising a composite material or a metal-containing material;
- constraining the outer section with a shrink-wrap material;
- connecting the inner and outer sections to the at least one intermediate layer;
- and
- removing the shrink-wrap material and the mandrel.
4 more elements
A method for making a shaped, contoured structural member, comprising:
- providing an inner section containing a continuous plurality of contoured layers comprising a composite material or a metal-containing material over a substantially-straight mandrel;
- roll wrapping at least one intermediate layer over the inner section, the at least one intermediate layer having a ribbed structure;
- providing an outer section over the at least one intermediate layer, the outer section containing a continuous plurality of contoured layers comprising a composite material or a metal-containing material;
- removing the mandrel;
- modifying the shape of the inner section, at least one intermediate layer, and the outer section to a substantially non-straight shape;
- constraining the outer section with a shrink-wrap material;
- connecting the inner and outer sections to the at least one intermediate layer;
- and
- removing the shrink-wrap material and the mandrel.
6 more elements
A shaped, contoured structural member made by the method comprising:
- providing an inner section containing a continuous plurality of contoured layers comprising a composite material or a metal-containing material over a shaped mandrel;
- roll wrapping at least one intermediate layer over the inner section, the at least one intermediate layer having a honeycomb core structure;
- providing an outer section over the at least one intermediate layer, the outer section comprising a continuous plurality of contoured layers comprising a composite material or a metal-containing material;
- and
- connecting the inner and outer sections to the at least one intermediate layer.
2 more elements
A shaped, contoured structural member made by the method comprising:
- providing an inner section containing a continuous plurality of contoured layers comprising a composite material or a metal-containing material over a substantially straight mandrel;
- roll wrapping at least one intermediate layer over the inner section, the at least one intermediate layer having a ribbed structure;
- providing an outer section over the at least one intermediate layer, the outer section containing a continuous plurality of contoured layers comprising a composite material or a metal-containing material;
- removing the mandrel;
- modifying the shape of the inner section, at least one intermediate layer, and the outer section to a substantially non-straight longitudinal shape;
- and
- connecting the inner and outer sections to the at least one intermediate layer.
4 more elements
A shaped, contoured structural member made by the method comprising:
- providing an inner section containing a continuous plurality of contoured layers comprising a composite material or a metal-containing material over a shaped mandrel;
- roll wrapping at least one intermediate layer over the inner section, the at least one intermediate layer having a honeycomb core structure;
- providing an outer section over the at least one intermediate layer, the outer section containing a continuous plurality of contoured layers comprising a composite material or a metal-containing material;
- constraining the outer portion with a shrink-wrap material;
- connecting the inner and outer sections to the at least one intermediate layer;
- and
- removing the shrink-wrap material and the mandrel.
4 more elements
A shaped, contoured structural member made by the method comprising:
- providing an inner section containing a continuous plurality of contoured layers comprising a composite material or a metal-containing material over a substantially straight mandrel;
- roll wrapping at least one intermediate layer over the inner section, the at least one intermediate layer having a ribbed structure;
- providing an outer section over the at least one intermediate layer, the outer section containing a continuous plurality of contoured layers comprising a composite material or a metal-containing material;
- removing the mandrel;
- modifying the shape of the inner section, at least one intermediate layer, and the outer section to a substantially non-straight longitudinal shape;
- constraining the outer section with a shrink-wrap material;
- connecting the inner and outer sections to the at least one intermediate layer;
- and
- removing the shrink-wrap material and the substrate.
6 more elements
Dependencies are inferred from the claim text.