Gm Global Technolgoy Operations, Inc.

University of Illinois

Ruoyu Sun

Nilesh D Mankame

Girish Krishnan

A structural component for a vehicle includes a component including an interior surface defining a first hollow passage and a structural reinforcement contacting the interior surface of the component. The structural reinforcement and component define a cross-section and the structural reinforcement partially fills the cross-section. A process for forming the structural component including inserting a bladder into the first hollow passage defined by the interior surface of the component and inflating the bladder in the first hollow passage, forming a cavity between the bladder and the interior surface, filling the cavity with a polymer resin, and foaming the polymer resin. A system for forming a structural component for a vehicle includes a component including a first hollow passage defined by an interior surface of the component, a bladder insertable into the first hollow passage of the component, and a supply line connected to an interior of the bladder.

Inflatable-based process for controlling structural foam reinforcement molding

A structural component for a vehicle and a process and system for forming the structural component. A first cavity is formed in a first hollow passage between a first bladder and an interior surface of a component forming the structural component. A first structural reinforcement layer is formed in the first cavity by filling the first cavity with a first polymer resin and foaming the first polymer resin to form a first polymer resin foam. A second cavity is formed in the first hollow passage and a second structural reinforcement layer is formed in the second cavity by filling the second cavity with a second polymer resin and foaming the second polymer resin to form a second polymer resin foam.

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Champaign, IL, United States of America

Ruoyu Sun