U.S. patent application number 14/270951 was filed with the patent office on 2015-11-12 for hybrid composite instrument panel.
This patent application is currently assigned to Ford Global Technologies, LLC. The applicant listed for this patent is Ford Global Technologies, LLC. Invention is credited to Tim Beard, Kalyanaraman Bharathan, Jeff Webb.
Application Number | 20150321560 14/270951 |
Document ID | / |
Family ID | 54336776 |
Filed Date | 2015-11-12 |
United States Patent
Application |
20150321560 |
Kind Code |
A1 |
Webb; Jeff ; et al. |
November 12, 2015 |
HYBRID COMPOSITE INSTRUMENT PANEL
Abstract
A vehicular instrument panel having a reinforcement that
includes a plurality of chopped carbon fibers within a nylon resin,
and a substrate coupled to the reinforcement comprising a plurality
of chopped carbon and chopped glass fibers within a nylon resin.
The plurality of chopped carbon and glass fibers in the substrate
are segregated such that the carbon fibers and the glass fibers are
each substantially concentrated within respective driver-side and
passenger-side portions of the substrate. The substrate can also
include a boundary region such that the plurality of chopped carbon
and glass fibers in the substrate are substantially mixed in the
boundary region.
Inventors: |
Webb; Jeff; (Iron Mountain,
MI) ; Bharathan; Kalyanaraman; (Canton, MI) ;
Beard; Tim; (Perry, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ford Global Technologies, LLC |
Dearborn |
MI |
US |
|
|
Assignee: |
Ford Global Technologies,
LLC
Dearborn
MI
|
Family ID: |
54336776 |
Appl. No.: |
14/270951 |
Filed: |
May 6, 2014 |
Current U.S.
Class: |
296/70 |
Current CPC
Class: |
B62D 25/06 20130101;
B62D 29/043 20130101; B29C 45/0005 20130101; B29K 2105/12 20130101;
B29L 2031/3008 20130101; B29C 45/16 20130101; B62D 25/14 20130101;
B60K 37/00 20130101 |
International
Class: |
B60K 37/00 20060101
B60K037/00 |
Claims
1. A vehicular instrument panel, comprising: a reinforcement
comprising a plurality of chopped carbon fibers within a nylon
resin; and a substrate coupled to the reinforcement comprising a
plurality of chopped carbon and chopped glass fibers within a nylon
resin, wherein the plurality of chopped carbon and glass fibers in
the substrate are segregated such that the carbon fibers and the
glass fibers are each substantially concentrated within respective
driver-side and passenger-side portions of the substrate, and
further wherein the substrate further comprises a boundary region
in a center-stack portion of the substrate, and the plurality of
chopped carbon and glass fibers in the substrate are substantially
mixed in the boundary region.
2. The vehicular instrument panel of claim 1, wherein the plurality
of chopped carbon fibers in the substrate has a fiber volume
fraction in the nylon resin of about 15% to about 40%.
3. The vehicular instrument panel of claim 1, wherein the plurality
of chopped carbon and chopped glass fibers in the substrate are
further segregated such that the carbon fibers are substantially
concentrated in the driver-side portion and the center-stack
portion of the substrate.
4. The vehicular instrument panel of claim 1, wherein the chopped
carbon fibers in the substrate have an average fiber length of
about 5 mm to about 7 mm.
5. (canceled)
6. The vehicular instrument panel of claim 5, wherein the plurality
of chopped carbon fibers in the driver-side portion of the
substrate has a fiber volume fraction of about 30% to 40% in the
nylon resin, the plurality of chopped glass fibers in the
passenger-side portion has a fiber volume fraction of about 30% to
40% in the nylon resin, and the plurality of chopped carbon fibers
and the plurality of chopped glass fibers in the boundary region
each have a fiber volume fraction of about 15% to 20% in the nylon
resin.
7. A vehicular instrument panel, comprising: a first member
comprising a fiber material within a first resin; and a second
member coupled to the first member having driver-side,
passenger-side, and center-stack portions, wherein the driver-side
portion comprises a first fiber material within a second resin, the
passenger-side portion comprises a boundary region having a second
fiber material within the second resin, and the center-stack
portion comprises a mixture of the first and second fiber materials
within the second resin.
8. The vehicular instrument panel of claim 7, wherein the first and
second fiber materials are each selected from the group of
materials consisting of carbons, aramids, aluminum metals, aluminum
oxides, steels, borons, silicas, silicon carbides, silicon
nitrides, ultra-high-molecular-weight polyethylenes, A-glasses,
E-glasses, E-CR-glasses, C-glasses, D-glasses, R-glasses, and
S-glasses.
9. The vehicular instrument panel of claim 7, wherein the first and
second resins are each selected from the group of materials
consisting of a nylon, a polypropylene, an epoxy, a polyester, a
vinyl ester, a polyetheretherketone, a poly(phenylene sulfide), a
polyetherimide, a polycarbonate, a silicone, a polyimide, a
poly(ether sulfone), a melamine-formaldehyde, a
phenol-formaldehyde, and a polybenzimidazole.
10. The vehicular instrument panel of claim 7, wherein the first
and second resins have substantially the same composition.
11. The vehicular instrument panel of claim 7, wherein the
driver-side and passenger-side portions of the second member each
have a fiber volume fraction of the respective first and second
fiber materials in the second resin of about 15% to about 40%.
12. The vehicular instrument panel of claim 11, wherein the first
fiber material in the driver-side portion has a first fiber volume
fraction of about 30% to 40% in the second resin, the
passenger-side portion has a second fiber volume fraction of about
30% to 40% in the second resin, and the first and second fiber
materials in the center-stack portion each have a fiber volume
fraction of about 15% to 20% in the second resin.
13. The vehicular instrument panel of claim 7, wherein the first
and second fiber materials each have an average fiber length of
about 5 mm to about 7 mm.
14. The vehicle instrument panel of claim 7, wherein the
passenger-side portion of the second member further comprises a
fiber mat reinforcement.
15. A vehicular component, comprising: a first portion comprising a
first fiber material within a first resin; a second portion
comprising a second fiber material within a second resin; and a
boundary region between the first and second portions having a
mixture of the first and second fiber materials within the first
and second resins, wherein the first and the second portions are in
substantial proximity to respective driver-side and passenger-side
sections in a vehicle.
16. The vehicular component of claim 15, wherein the first and
second fiber materials are each selected from the group of
materials consisting of carbons, aramids, aluminum metals, aluminum
oxides, steels, borons, silicas, silicon carbides, silicon
nitrides, ultra-high-molecular-weight polyethylenes, A-glasses,
E-glasses, E-CR-glasses, C-glasses, D-glasses, R-glasses, and
S-glasses.
17. The vehicular component of claim 15, wherein the first and
second resins are each selected from the group of materials
consisting of a nylon, a polypropylene, an epoxy, a polyester, a
vinyl ester, a polyetheretherketone, a poly(phenylene sulfide), a
polyetherimide, a polycarbonate, a silicone, a polyimide, a
poly(ether sulfone), a melamine-formaldehyde, a
phenol-formaldehyde, and a polybenzimidazole.
18. The vehicular component of claim 15, wherein the first and
second portions each have a fiber volume fraction of the respective
first and second fiber materials in the respective first and second
resins of about 15% to about 40%.
19. The vehicular component of claim 18, wherein the first fiber
material in the first portion has a fiber volume fraction of about
30% to 40% in the first resin, the second fiber material in the
portion has a fiber volume fraction of about 30% to 40% in the
second resin, and the first and second fiber materials in the
boundary region each have a fiber volume fraction of about 15% to
20% in the mixture of the first and second resins.
20. The vehicular component of claim 15, wherein the first and
second fiber materials each have an average fiber length of about 5
mm to about 7 mm.
Description
FIELD OF THE INVENTION
[0001] The present disclosure generally relates to composite
component designs, and more particularly relates to composite
vehicular instrument panel designs and methods for making the
same.
BACKGROUND OF THE INVENTION
[0002] It is becoming more common for vehicles to utilize
lightweight components and designs in order to decrease vehicle
weight, particularly in large, interior vehicle components such as
instrument panels. Weight reductions can increase vehicle
performance and fuel economy. Weight savings may be realized by
substituting current materials of vehicle components with lighter
weight materials. However in some cases, lighter weight materials
employed in vehicles can have less mechanical integrity than their
heavier weight counterparts.
[0003] In other cases, certain lighter weight materials, such as
carbon fiber composites, can actually have improved mechanical
performance over conventional materials. Unfortunately, the
manufacturing costs of making vehicular components with these
materials can be prohibitive or at least not low enough to offset
the potential improvements in vehicle performance and fuel economy.
Further, these stronger composite materials are often employed in
large vehicular components that have only one or a handful of
regions that actually require elevated mechanical performance.
[0004] Accordingly, there is a need for lighter-weight vehicular
components having better or comparable mechanical performance when
compared to conventional vehicular components. There is also a need
to tailor the mechanical properties in particular regions within
these components for the particular application, thus minimizing
the use of expensive reinforcing materials and maximizing
mechanical property enhancements where it is required in the
component.
SUMMARY OF THE INVENTION
[0005] According to one aspect of the present disclosure, a
vehicular instrument panel includes a reinforcement comprising a
plurality of chopped carbon fibers within a nylon resin and a
substrate coupled to the reinforcement. The substrate includes a
plurality of chopped carbon and chopped glass fibers within a nylon
resin. The plurality of chopped carbon and glass fibers in the
substrate are segregated such that the carbon fibers and the glass
fibers are each substantially concentrated within respective
driver-side and passenger-side portions of the substrate.
[0006] According to another aspect of the present disclosure, a
vehicular instrument panel includes a first member having a fiber
material within a first resin and a second member coupled to the
first member. The second member has driver-side, passenger-side,
and center-stack portions. The driver-side portion has a first
fiber material within a second resin, the passenger-side portion
has a second fiber material within the second resin, and the
center-stack portion has a mixture of the first and second fiber
materials within the second resin.
[0007] According to a further aspect of the present disclosure, a
vehicular component includes a first portion having a first fiber
material within a first resin and a second portion that includes a
second fiber material within a second resin. A boundary region has
a mixture of the first and second fiber materials within the first
and second resins. The first and the second portions are in
substantial proximity to respective driver-side and passenger-side
sections in a vehicle.
[0008] These and other aspects, objects, and features of the
present invention will be understood and appreciated by those
skilled in the art upon studying the following specification,
claims, and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] In the drawings:
[0010] FIG. 1 is a front perspective view of a vehicular instrument
panel within a vehicle according to one embodiment;
[0011] FIG. 2 is an exploded top perspective view of the instrument
panel depicted in FIG. 1;
[0012] FIG. 3 is a bottom elevational view of a vehicular component
according to a further embodiment;
[0013] FIG. 4 is a top perspective view of an injection molding
system according to an additional embodiment;
[0014] FIG. 5A is a cross-sectional view of the injection molding
system of FIG. 4 during a step of injecting molten composites into
a mold, taken at line X-X;
[0015] FIG. 5B is a cross-sectional view of the injection molding
system of FIG. 4 during a step of cooling the melted composites,
taken at line X-X; and
[0016] FIG. 6 is a schematic of a method for forming a vehicular
component using the injection molding system of FIG. 4 according to
another embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] For purposes of description herein, the terms "upper,"
"lower," "right," "left," "rear," "front," "vertical,"
"horizontal," and derivatives thereof shall relate to the
disclosure as oriented in FIG. 1. However, it is to be understood
that the disclosure may assume various alternative orientations,
except where expressly specified to the contrary. It is also to be
understood that the specific devices and processes illustrated in
the attached drawings, and described in the following specification
are simply exemplary embodiments of the inventive concepts defined
in the appended claims. Hence, specific dimensions and other
physical characteristics relating to the embodiments disclosed
herein are not to be considered as limiting, unless the claims
expressly state otherwise.
[0018] Referring to FIG. 1, a cabin 10 of a vehicle 14 is depicted.
The vehicle 14 includes a driver-side region 18 and a
passenger-side region 22. Inside the cabin 10 is an instrument
panel 26, among other vehicle components, such as a windshield 36.
The instrument panel 26 is located vehicle forward in the cabin 10
beneath the windshield 36. The instrument panel 26 has a
driver-side portion 40, a center-stack portion 44, and a
passenger-side portion 48. These portions of the instrument panel
26, and particular regions or locations within them, often have
differing mechanical property requirements.
[0019] As used in this disclosure, "outboard" refers to the lateral
sides or regions most proximate to a driver-side door 52 and a
passenger-side door 56 in the vehicle 14. The term "inboard" as
used in this disclosure refers to a central area in the vehicle 14
inboard from the laterally opposing outboard sides or regions.
[0020] The driver-side and passenger-side portions 40, 48 of the
instrument panel 26 are in substantial proximity to respective
driver-side and passenger-side regions 18, 22 of the vehicle 14.
The driver-side portion 40 of the instrument panel 26 includes an
instrument cluster 60 covered by an instrument cluster hood 64.
Located below the instrument cluster 60 is a steering column 68.
The steering column 68 is supported by the instrument panel 26 and
engages a steering system (not shown) vehicle forward of the
instrument panel 26. The steering column 68 extends from the
steering system into the cabin 10 through the instrument panel 26.
The steering column 68 has a steering wheel 72 disposed in the
cabin 10 in the driver-side region 18 of the vehicle 14. The
steering wheel 72 includes a driver airbag 76 which deploys upon a
vehicle collision event. As such, the driver-side portion 40 of the
instrument panel 26 can have demanding mechanical requirements,
particularly at locations where it must support other vehicular
components subject to variable loads and motion, e.g., steering
column 68.
[0021] Still referring to FIG. 1, disposed on each outboard side of
the instrument panel 26 is a side air vent 80. The instrument panel
26 also incorporates a set of central air vents 84 located in the
center-stack portion 44 of the instrument panel 26. The
center-stack portion 44 of the instrument panel 26 is located
between the driver-side portion 40 and the passenger-side portion
48. The center-stack portion 44 includes an interface 88 that is
operable by occupants of both the driver-side and the
passenger-side regions 18, 22 of the vehicle 14. The center-stack
portion 44 is connected to both the driver-side portion 40 and the
passenger-side portion 48 of the instrument panel 26.
[0022] As also depicted in FIG. 1, the passenger-side portion 48 of
the instrument panel 26 includes a glove box assembly 110, and a
passenger airbag assembly 114 that is located above the assembly
110. The glove box assembly 110 includes a glove box door 118
permitting access to a glove box bin (not shown). In some
embodiments, the glove box assembly 110 is a separate component
from the instrument panel 26 and is inserted and attached during
manufacturing. In other embodiments, the glove box bin of the
assembly 110 is integrally formed from an instrument panel
substrate 120 (FIG. 2) of the instrument panel 26 and the glove box
door 118 is a separate component that is attached during
manufacturing. Depending on the configuration of passenger side
portion 48, it may have central regions or locations that require
additional mechanical reinforcement, such as where it contains or
attaches to glove box assembly 110.
[0023] Referring again to FIG. 1, the passenger airbag assembly 114
includes a passenger airbag chute 124 (FIG. 2), and other
components such as a passenger airbag, an airbag canister, and an
inflator. During a vehicle collision event, the passenger airbag is
inflated by the inflator (not shown), thereby causing the passenger
airbag to expand from the canister through the passenger airbag
chute 124 (FIG. 2) and out of the instrument panel 26. The
inflation and expansion of the airbag generates high stresses in
surrounding components which can lead to structural failure of the
instrument panel 26 if not properly reinforced. In some
embodiments, the instrument panel substrate 120 (FIG. 2) of the
instrument panel 26 may also include knee airbag canisters for the
occupants of both the driver-side and passenger-side regions 18,
22, potentially necessitating additional reinforcement.
[0024] Referring now to FIG. 2, the instrument panel 26 includes
the instrument panel substrate 120 and a reinforcement 150. The
reinforcement 150 is located vehicle forward of the substrate 120
and is coupled to the substrate 120 at multiple points. The
substrate 120 and the reinforcement 150 may be coupled via adhesive
bonding, vibration welding, hot plate welding, or other forms of
joining The reinforcement 150 includes a driver-side portion 154, a
center-stack portion 158, and a passenger-side portion 162. The
reinforcement 150 defines a steering column aperture 166 and a
glove box aperture 170 on the respective driver-side and
passenger-side portions 154, 162. Flanges 174 are located within
the center-stack portion 158 of the reinforcement 150 and extend
vehicle rearward to engage and couple with a center-stack portion
180 of the substrate 120.
[0025] As also depicted in FIG. 2, the instrument panel substrate
120 includes a driver-side portion 184, the center-stack portion
180, and a passenger-side portion 188. The driver-side portion 184
of the substrate 120 defines a steering column opening 192 which
aligns with the steering column aperture 166 of the reinforcement
150 when the substrate 120 and the reinforcement 150 are coupled.
The steering column 68 (FIG. 1) passes through both the steering
column aperture 166 and the steering column opening 192, and is
attached to the substrate 120 via a steering column mounting area
196, as shown in FIG. 2. The steering column mounting area 196 is
located on the substrate 120 proximate to the steering column
opening 192. In some embodiments, a jacket for the steering column
68 may be integrally formed in the substrate 120 proximate to the
mounting area 196. In other embodiments, a mounting bracket or a
support bracket may be integrally formed in the substrate 120
proximate to the steering column opening 192 for supporting the
steering column 68. The coupling of the reinforcement 150 to the
substrate 120 provides sufficient strength for the mounting area
196, and ultimately the instrument panel 26, to support the weight
of the steering column 68 without the use of a cross-car beam. As
such, certain regions or locations in the driver-side portion 184
of the substrate 120 may require and/or benefit from additional
reinforcement.
[0026] Still referring to FIG. 2, the center-stack portion 180 of
the instrument panel substrate 120 includes an electronics bay 200
for housing and mounting the interface 88 (FIG. 1) as well as other
electronic components. The center-stack portion 180 is located
between and is integrally connected to both the driver-side and
passenger-side portions 184, 188 of the substrate 120. Depending on
the electronic components and other components deployed in the
center-stack portion 180, additional localized reinforcement in the
substrate 120 with hybrid composites in these regions could provide
mechanical performance and/or weight savings benefits.
[0027] The passenger-side portion 188 of the instrument panel
substrate 120 defines a glove box opening 204 and a passenger
airbag assembly opening 208 for housing the respective glove box
assembly 110 (FIG. 1) and passenger airbag assembly 114 (FIG. 1).
In some embodiments, the substrate 120 may be configured to further
define a glove box bin and/or an airbag canister as integral bodies
that extend from the respective glove box and passenger airbag
assembly openings 204, 208. In other embodiments, the reinforcement
150 could be configured to define a glove box bin and/or an airbag
canister. The substrate 120 and the reinforcement 150 can also be
configured to define knee airbag canisters.
[0028] As also depicted in FIG. 2, a duct 212 is located between
the instrument panel substrate 120 and the reinforcement 150. The
duct 212 conveys air when bonded to the reinforcement 150. The air
travels though the duct 212 to a set of substrate vent openings 216
which direct the air to the side and central air vents 80, 84 of
the instrument panel 26 (FIG. 1). Attached to the reinforcement 150
is a plenum bracket 220 which connects with a firewall (not shown)
of the vehicle 14. The plenum bracket 220 prevents bending of the
instrument panel 26 in a vehicle forward and rearward direction.
The plenum bracket 220 can also provide additional support for the
steering column 68 (FIG. 1), coupled to the substrate 120.
[0029] Referring again to FIG. 2, the instrument panel substrate
120 is formed from a hybrid composite material according to an
embodiment of this disclosure. In one exemplary embodiment, the
driver-side portion 184 can be formed from a nylon resin having
chopped carbon fibers disposed in the resin. The passenger-side
portion 188 can be formed from a nylon resin having chopped glass
fibers disposed in the resin. In general, regions in the substrate
120 with higher percentages of chopped carbon fibers can have
enhanced mechanical properties (e.g., toughness, tensile strength,
fatigue resistance). The carbon fiber volume fraction and the glass
fiber volume fraction in the passenger-side and driver-side
portions 184, 188 may be between about 1% and about 60%, preferably
between about 15% and about 40%, and more preferably between about
30% to about 40%. In some embodiments, the fiber volume fraction in
the driver-side portion 184 may be different from the fiber volume
fraction in the passenger-side portion 188 of the substrate 120. In
additional embodiments, areas of the substrate 120 that are
anticipated to encounter high stresses are configured to
incorporate higher fiber volume fractions of chopped carbon fibers
than areas not expected to experience high stresses. For example,
the mounting area 196 may incorporate a higher fiber volume
fraction, particularly of chopped carbon fibers, than the rest of
the driver-side portion 184 of the substrate 120 to aid in
supporting the steering column 68. In another example, the surfaces
of the instrument panel substrate 120 and reinforcement 150 subject
to high stress during airbag deployment may incorporate higher
fiber volume fractions. In further embodiments, the driver-side and
passenger-side portions 184, 188 of the substrate 120 may
incorporate more than two composite materials.
[0030] In some embodiments, the fibers employed in the driver-side
and passenger-side portions 184, 188 of the instrument panel
substrate 120 can be composed of materials including carbons,
aramids, aluminum metals, aluminum oxides, steels, borons, silicas,
silicon carbides, silicon nitrides, ultra-high-molecular-weight
polyethylenes, A-glasses, E-glasses, E-CR-glasses, C-glasses,
D-glasses, R-glasses, and S-glasses. Driver-side and passenger-side
portions 184, 188 may also incorporate more than one type of fiber.
In some embodiments, the length of the chopped fibers can be
between about 3 mm and about 11 mm, and more preferably between
about 5 mm and about 7 mm. Typically, the fibers are randomly
oriented in the resins within the driver-side and passenger-side
portions 184, 188. However, they may also be substantially aligned
directionally in areas of the substrate 120 subject to high
directional stresses. Further, the resins employed in the
driver-side and passenger-side portions 184, 188 can comprise a
nylon, a polypropylene, an epoxy, a polyester, a vinyl ester, a
polyetheretherketone, a poly(phenylene sulfide), a polyetherimide,
a polycarbonate, a silicone, a polyimide, a poly(ether sulfone), a
melamine-formaldehyde, a phenol-formaldehyde, and a
polybenzimidazole, or combinations thereof. In some embodiments,
the resin of the driver-side portion 184 may be different from the
resin employed in the passenger-side portion 188 of the substrate
120. It should also be understood that the reinforcement 150 and
its driver-side, center-stack and passenger-side portions 154, 158,
162 can be fabricated with hybrid composite materials comparable to
those described above in connection with substrate 120. For
example, the driver-side portion 154 of the reinforcement 150 can
be formed from a nylon resin having chopped carbon fibers disposed
in the resin. The passenger-side portion 162 can be formed from a
nylon resin having chopped glass fibers disposed in the resin.
Further, the volume fraction of the fibers in the resins,
preferably the chopped carbon fibers, may be greater in areas
subject to higher stress levels than in the rest of the
reinforcement 150.
[0031] Still referring to FIG. 2, the chopped carbon and glass
fibers are segregated in the substrate 120 of the instrument panel
26 such that the carbon fibers are substantially concentrated in
the driver-side portion 184 of the substrate 120 and the glass
fibers are substantially concentrated in the passenger-side portion
188 of the substrate 120. In general, the center-stack portion 180
of the substrate 120 is composed of both chopped carbon and glass
fibers. In some embodiments, the center-stack portion 180 may
primarily include carbon fibers, or primarily glass fibers. In
other embodiments, the carbon fibers primarily contained in the
driver-side portion 184 may also partially occupy the
passenger-side portion 188 of the substrate 120. In further
embodiments, the carbon fibers primarily in the driver-side portion
184 may also occupy portions of the substrate 120 which are subject
to high stress, regardless of passenger-side or driver-side
orientation. For example, airbag deployment surfaces located in or
on the substrate 120 or reinforcement 150 can include higher
percentages of carbon fibers for additional mechanical
reinforcement. The segregation of the fibers, e.g., chopped carbon
and glass fibers, in the substrate 120 allows the higher strength
fiber, e.g., carbon fiber, to be selectively used where there are
particular high strength needs for the substrate 120, such as to
support the steering column 68. The selective use of high
percentages of carbon fibers based on driver/passenger orientation
relative to the vehicle 14 allows a cost savings by efficiently
using the more expensive carbon fibers only where needed.
[0032] As also shown in FIG. 2, a boundary region 240 can exist in
some embodiments at the interface between the driver-side and
passenger-side portions 184, 188 of the instrument panel substrate
120. The boundary region 240 includes a mixture of both types of
fibers and resin(s) employed in the driver-side and passenger-side
portions 184, 188 of the substrate 120. The mixing of fibers within
the boundary region 240 ensures that an integral connection exists
between portions of the substrate 120 composed of different
composite materials. In one embodiment, the boundary region 240 may
span or otherwise encompass the entire center-stack portion 180 of
the substrate 120. In another embodiment, the boundary region 240
may be present only between the center-stack and passenger-side
portions 180, 188, or between the driver-side and center-stack
portions 184, 180 of the substrate 120. The boundary region 240 can
also be located anywhere in the substrate 120 where there is an
interface between portions of the substrate 120 containing
differing fiber fractions, fiber types and/or resins. In one
exemplary embodiment, driver-side portion 184 may have an
approximate 30% to 40% volume fraction of chopped carbon fibers in
a resin, the passenger-side portion 188 may have an approximate 30%
to 40% volume fraction of chopped glass fibers in the resin, and
the center-stack portion 180 or the boundary region 240 may have an
approximate 15% to 20% volume fraction of chopped carbon fibers and
an approximate 15% to 20% volume fraction of chopped glass fibers
in the resin. In this configuration, the driver-side portion 184 is
particularly reinforced with higher percentages of chopped carbon
fibers relative to other portions of the substrate 120.
[0033] According to some embodiments, the instrument substrate 120
and/or the reinforcement 150 of the instrument panel 26 may
incorporate one or more preformed fiber mats in addition to the
portions containing chopped fibers in a resin or resins. The
preformed fiber mats may include woven or non-woven fibers that are
held together using the same or different resins as employed in the
driver-side and passenger-side portions 184, 188 of the substrate
120. The mats may also incorporate fibers having different
dimensions from the fibers employed in the driver-side and
passenger-side portions 184, 188 of the substrate 120. Similarly,
the fibers of the mats may be in either a continuous or chopped
configuration. The fibers of the mats may also be composed of a
material having the same or a different composition from that of
the fibers employed in the driver-side and passenger-side portions
184, 188 of the substrate 120. The mats may be incorporated in
areas of the substrate 120 and/or the reinforcement 150 having high
or low fiber volume fractions. Multiple mats may be used and
layered in varying orientations in order to further enhance the
mechanical properties of the substrate 120 and/or reinforcement 150
at particular locations. Exemplary locations in the substrate 120
for placement of the mat include, but are not limited to: the
steering column mounting area 196, airbag assembly opening 208,
glove box opening 204, coupling locations between the reinforcement
150 and the substrate 120, and other locations anticipated to
experience higher stress levels compared to stresses in other areas
of the substrate 120.
[0034] The utilization of a hybrid composite containing carbon
fibers in the substrate 120 and the reinforcement 150 permits the
vehicle 14 to be designed and manufactured without a cross-car
beam. Conventional cross-car beams are thick metal components
traditionally used to support the instrument panel 26 and the
steering column 68 of the vehicle 14. In addition to adding
significant weight to the vehicle 14, the cross-car beam occupies a
potential storage space behind the instrument panel 26 and
obstructs placement of the passenger airbag assembly and the glove
box assembly 110. Without the cross-car beam, the vehicle 14 can
achieve greater fuel efficiency as well as enhanced design freedom
for the instrument panel 26 and its subassemblies.
[0035] Referring now to FIG. 3, the foregoing aspects of the
instrument panel substrate 120 and reinforcement 150 (see FIGS. 1
and 2 and the corresponding description) can extend to other
components, such as a vehicular component 250. Here, component 250
has a first portion 254 comprising a first fiber material 258
within a first resin 262. The component 250 also has a second
portion 266 including a second fiber material 270 within a second
resin 274. Between the first and second portions 254, 266 of the
component 250 is a component boundary region 278 having a mixture
of the first and second fiber materials 258, 270 within the first
and second resins 262, 274. The first and second portions 254, 266
can be in substantial proximity to respective passenger-side and
driver-side regions 18, 22 (FIG. 1). As depicted schematically in
FIG. 3, component 250 can be a headliner for the cabin 10 of the
vehicle 14. But it should be understood that component 250 may be
another component located inside or on the vehicle 14 (FIG. 1)
suitable for fabrication from a hybrid composite according to the
foregoing principles. The first and second fiber materials 258, 270
of the component 250 may be selected from the same group of fibers
employed in the substrate 120. Further, the first and second fiber
materials 258, 270 employed in the first and second portions 254,
266 may have the same or comparable fiber length and fiber volume
fractions as the driver-side and passenger-side portions 184, 188
of the substrate 120. Similarly, the first and second resins 262,
274 of the component 250 can have a composition comparable to the
resin or resins employed in the substrate 120. Further, the
component 250 may incorporate a fiber mat comparable to the fiber
mat described earlier in connection with the substrate 120.
[0036] Referring now to FIG. 4, an injection molding system 300 is
depicted that includes a heater 302, a pump 304, a controller 308,
a mold 312, and a pair of injection lines 316 according to one
embodiment. The heater 302 melts a first composite 230 and a second
composite 234 and the pump 304 pressurizes and forces the melted
first and second composites 230, 234 through the injection lines
316, and into the mold 312 via connection ports 320. The pump 304
is capable of producing high fluid pressures which permit the first
and second composites 230, 234 to be injected into the mold 312 at
high pressures and speeds. Each injection line 316 engages one of
the connection ports 320 on the mold 312 such that the first and
second composites 230, 234 can enter the mold 312 at different
locations. In some embodiments of system 300, more than two
composite materials can be injected into the mold 312. In these
configurations, the injection molding system 300 can include
separate injection lines 316 for each material and the mold 312 may
contain separate connection ports 320 for each additional injection
line 316.
[0037] When solidified, the first and second composite materials
230, 234 of FIG. 4 are suitable for formation of a final component,
e.g., the instrument panel substrate 120, reinforcement 150,
component 250. The first composite 230 includes the first fiber
material 258 within the first resin 262. Similarly, the second
composite 234 includes the second fiber material 270 within the
second resin 274. Accordingly, the first and second fiber materials
258, 270 and the first and second resins 262, 274 may be composed
of any of the respective fibers and resins disclosed in conjunction
with the instrument panel substrate 120, the reinforcement 150, or
the component 250.
[0038] Again referring to FIG. 4, the mold 312 has an A-plate 324
and a B-plate 328, each plate defining approximately half of a
cavity 332 of the mold 312. The A-plate 324 includes the connection
ports 320 through which the first and second composite materials
230, 234 enter the mold 312. The A- and B-plates 324, 328 each
contain an impression of one half of the final vehicular component
(e.g., vehicular component 250, substrate 120, reinforcement 150,
etc.) such that when the mold 312 is closed, the negative
impressions define the mold cavity 332 with the approximate
dimensions of the final component. In some embodiments, the mold
312 may include inserts and/or subassemblies to aid in formation of
the final component.
[0039] As shown in FIG. 5A, the mold 312, when configured to form a
substrate 120, has a driver-side portion 336, a center-stack
portion 340, and a passenger-side portion 344 oriented to form the
respective portions 184, 180, 188 of the substrate 120 (FIG. 2).
During injection of the melted first and second composites 230,
234, a pressure is exerted on the mold 312 such that the A-plate
324 and the B-plate 328 are forced together. The force acting on
the mold 312 prevents mold separation and flashing from occurring
on the substrate 120. The mold 312, while depicted in a closed
state in FIG. 5A, may be opened by separating the A-plate 324 and
the B-plate 328. While the mold 312 is in an open state, the
substrate 120 may be ejected, and the mold 312 and cavity 332 can
then be cleaned. The injection molding system 300 employing mold
312 may also be used in a like manner as described above to form
the reinforcement 150, the plenum bracket 220, the vehicular
component 250, or a variety of other vehicle components suitable
for being fabricated with hybrid composites.
[0040] Referring now to FIG. 6, a schematic of a method 360
configured for formation of a final component, such as the
substrate 120 of the instrument panel 26, is provided. The method
360 includes five primary steps, steps 364, 368, 372, 376, and 380.
The method 360 begins with step 364 of melting the first and second
composites 230, 234, followed by step 368 of preparing the
injection molding system 300. Next, the step 372 of injecting the
first and second melted composite materials 230, 234 into the
cavity 332 of the mold 312 is performed. The step 376 of cooling
the melted first and second composites 230, 234 to form the final
component, e.g., substrate 120 of the instrument panel 26, is
conducted next. Finally, the step 380 of removing the final
component from the mold 312 is performed.
[0041] Referring to FIGS. 4-6, step 364 involves heating the first
and second composites 230, 234 in the heater 302 to a temperature
sufficient to melt the resin constituents. With the resins melted,
the pump 304 is able to push the melted first and second composites
230, 234 through the injection lines 316 and into the cavity 332 of
the mold 312 via the connection ports 320. The first and second
composites 230, 234, particularly when comprising nylon resin, can
be injected at a temperature between 100.degree. C. and 400.degree.
C., and more preferably between 210.degree. C. and 275.degree. C.
The melted first and second composites 230, 234 typically are
superheated to a sufficiently high temperature to prevent their
premature solidification in the injection lines 316 before reaching
the cavity 332. As used herein, the term "superheat" refers to the
temperature difference between the melting temperature and the
injection temperature of the first and second composites 230, 234.
The superheat is also necessary to ensure that the first and second
composites 230, 234 have sufficiently low viscosity to enter narrow
areas of the cavity 332. The superheat may be between 10.degree. C.
and 50.degree. C. for composites 230, 234. Other injection
temperatures and superheat conditions may be appropriate depending
on the compositions selected for the composites 230, 234, geometry
of the mold 312, and other conditions.
[0042] Step 368 of preparing the injection molding system 300 may
include tasks such as preheating the mold 312, priming the
injection lines 316, and/or placing a preassembled fiber mat or
multiple mats into the cavity 332 of the mold 312. Step 372 of
injecting the first and second composites 230, 234 may have a
duration of between 5 seconds and 30 seconds, and more preferably
between 10 seconds and 20 seconds. Other durations may be
appropriate for more complex mold cavity 332 geometries and/or
lower melt viscosity compositions for the composites 230, 234. In
some embodiments, the injection of the melted first and second
composites 230, 234 may be simultaneous, while in other
embodiments, each composite is injected separately. During the
injection step 372, the melted first and second composites 230, 234
are injected into respective driver-side and passenger-side
portions 336, 344 of the mold 312 (see FIG. 5A), thereby causing
substantial segregation of the fibers in the final component, e.g.,
substrate 120. The composites 230, 234 may also be injected at
other points in the cavity 332 to create the desired segregation or
other properties.
[0043] Referring again to FIGS. 4-6, step 376 of cooling the melted
first and second composites 230, 234 to form the final component,
e.g., substrate 120, occurs while the mold 312 is held under
pressure and chilled. The mold 312 may be water chilled or may be
air chilled to promote solidification of the final component. After
solidification of the substrate 120, the mold is opened and step
380 of removing the final component is carried out by actuating a
series of ejection pins (not shown) to eject the final component
from the B-plate 328 of the mold 312.
[0044] With particular reference to FIG. 5A, a cross section of the
mold 312 configured to produce the substrate 120 is depicted during
the step 372 of injecting the first and second composite materials
230, 234 into the cavity 332 of the mold 312. The first and second
composites 230, 234 are injected through a series of gates (not
shown). The cavity 332 may be filled by injection of the first and
second composites 230, 234 into respective driver-side and
passenger-side portions 336, 344 of the cavity 332. Upon entering
the mold 312, the melted first and second composites 230, 234
fluidly flow through the cavity 332 toward each other.
[0045] Referring now to FIG. 5B, at a predetermined location in the
cavity 332, the melted first and second composites 230, 234
continue to flow toward each other to combine to form the boundary
region 240. The boundary region 240 includes a mixture of fibers
and resins from the first and second composites 230, 234 and may
have a width between 1 mm and 50 mm. The location and width of the
boundary region 240 is controlled through design of the mold 312,
processing parameters of the injection molding system 300 and the
particular composition selected for the first and second composites
230, 234. The processing parameters may be controlled by the
controller 308 (FIG. 4). In one exemplary embodiment, more than two
composite materials having different compositions may be injected
into the cavity 332 during the injection step 372. In this
configuration, there can be a boundary region 240 between each of
the composite materials such that each boundary region 240 has a
different composition from the others. Upon cooling and
solidification of the first and second composites 230, 234, the
mixture of the resins and fibers within the boundary region 240
creates an integral connection between the first composite material
230 and the second composite material 234, thereby holding the
substrate 120 or other final component together.
[0046] It is to be understood that variations and modifications can
be made on the aforementioned structure without departing from the
concepts of the present invention. For example, the present
disclosure of a hybrid composite and its method of manufacture
could be equally applied to the grille of a motor vehicle.
Attachment points in a hybrid composite grille, for example, may
require added reinforcement in the form of chopped carbon fibers.
Further, it is to be understood that such concepts are intended to
be covered by the following claims unless these claims by their
language expressly state otherwise.
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