US4978562A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Composite tubular door beam reinforced with a syntactic foam core localized at the mid-span of the tube
Assignee: Henkel Corp
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Filing: 1990-02-05
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Granted: 1990-12-18
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Expires: 2010-02-05
Abstract
Abstract A lightweight, composite beams for reinforcing a vehicle door is provided. The reinforcing beam comprises a metal tube having a longitudinal cavity which is partially filled with a reinforcing polymeric core which in one aspect includes a thermoset or thermoplastic resin-based material. The 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.
Inventors
- 👤 Joseph S. Wycech
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-05 15:32
CPC Classifications
B; B60; B60J; B60J5/00; B60J5/04; B60J5/042; B60J5/0452; B60J5/0422; B60J5/0438; B60J5/0443; B60J5/0444; B60J5/0447; Y; Y10; Y10T; Y10T428/00; Y10T428/13; Y10T428/1352; Y10T428/1355; Y10T428/1376; Y10T428/23; Y10T428/233
Claims Analysis
Total Claims: 23
Claim 1
Independent Claim
166 words
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 resin-based core disposed in said bore of said metal tube, said bore 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; and 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.
Claim 2
Dependent Claim
166 words
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 resin-based core disposed in said bore of said metal tube, said bore 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; and 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.
Claim 3
Dependent Claim
23 words
The lightweight, composite door beam recited in claim 1, wherein said door beam is mounted to said inner panel of said vehicle door.
Claim 4
Dependent Claim
43 words
The lightweight, composite door beam recited in claim 1, wherein said core includes from about 35 to about 95 by weight synthetic resin, from about 1 to about 60 by weight cell-forming agent, and from about 1.0 to about 55 by weight filler.
Claim 5
Dependent Claim
28 words
The lightweight, composite door beam recited in claim 1, wherein said first and second mounting means are end pieces and said end pieces are integral with said body.
Claim 6
Dependent Claim
24 words
The lightweight, composite door beam recited in claim 3, wherein said synthetic resin is selected from the group consisting of thermoplastic and thermosetting resins.
Claim 7
Dependent Claim
15 words
The lightweight, composite door beam recited in claim 3, wherein said cell-forming agent comprises microspheres.
Claim 8
Dependent Claim
30 words
The lightweight, composite door beam recited in claim 3, wherein said cell-forming agent comprises a blowing agent selected from the group consisting of chemical blowing agents and physical blowing agents.
Claim 9
Dependent Claim
34 words
The lightweight, composite door beam recited in claim 3, wherein said filler is selected from the group consisting of glass microspheres, plastic microspheres, fumed silica, calcium carbonate, milled glass fiber and chopped glass strand.
Claim 10
Dependent Claim
111 words
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; a resin-based 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.
Claim 11
Dependent Claim
111 words
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; a resin-based 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.
Claim 12
Dependent Claim
40 words
The invention recited in claim 9, wherein said core includes from about 35 to about 95 by weight synthetic resin, from about 1 to about 60 by weight cell-forming agent and from about 1.0 to about 55 by weight filler.
Claim 13
Dependent Claim
25 words
The invention recited in claim 9, wherein said first and second mounting means are end pieces and said end pieces are integral with said body.
Claim 14
Dependent Claim
21 words
The invention recited in claim 9, wherein said synthetic resin is selected from the group consisting of thermoplastic and thermosetting resins.
Claim 15
Dependent Claim
15 words
The lightweight, composite door beam recited in claim 9, wherein said cell-forming agent comprises microspheres.
Claim 16
Dependent Claim
30 words
The lightweight, composite door beam recited in claim 9, wherein said cell-forming agent comprises a blowing agent selected from the group consisting of chemical blowing agents and physical blowing agents.
Claim 17
Dependent Claim
34 words
The lightweight, composite door beam recited in claim 9, wherein said filler is selected from the group consisting of glass microspheres, plastic microspheres, fumed silica, calcium carbonate, milled glass fiber and chopped glass strand.
Claim 18
Independent Claim
71 words
A method of forming an impact beam comprising the following steps: (a) providing a metal tube defining a bore; (b) providing a resin-based core adapted to be received within said metal tube, said core having a length not greater than one-third the length of said metal tube; and (c) sliding said core into said bore of said metal tube such that said core occupies the mid span of said metal tube.
Claim 19
Independent Claim
71 words
A method of forming an impact beam comprising the following steps: (a) providing a metal tube defining a bore; (b) providing a resin-based core adapted to be received within said metal tube, said core having a length not greater than one-third the length of said metal tube; and (c) sliding said core into said bore of said metal tube such that said core occupies the mid span of said metal tube.
Claim 20
Dependent Claim
40 words
The invention recited in claim 1, wherein said core includes from about 35 to about 95 by weight synthetic resin, from about 1 to about 60 by weight cell-forming agent, and from about 1.0 to about 55.0 by weight filler.
Claim 21
Dependent Claim
22 words
The invention recited in claim 16, further including the steps of forming first and second mounting means integral with said metal tube.
Claim 22
Dependent Claim
21 words
The invention recited in claim 17, wherein said synthetic resin is selected from the group consisting of thermoplastic and thermosetting resins.
Claim 23
Dependent Claim
15 words
The lightweight, composite door beam recited in claim 17, wherein said cell-forming agent comprises microspheres.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1993-12-17 | 1994-06-18 | 1994-12-18 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1997-12-17 | 1998-06-18 | 1998-12-18 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2001-12-17 | 2002-06-18 | 2002-12-18 | $7700.00 | Window Closed / Lapsed |