US 11,858,239 B2
Polymer-graphene energy absorbing composite structures and methods of manufacture
Saida Khan, Canton, MI (US); Santosh Sarang, Novi, MI (US); and Masahiro Narita, Novi, MI (US)
Assigned to Aisin Technical Center of America, Inc., Northville, MI (US)
Filed by Aisin Technical Center of America, Inc., Northville, MI (US)
Filed on Sep. 22, 2021, as Appl. No. 17/481,732.
Prior Publication US 2023/0091672 A1, Mar. 23, 2023
Int. Cl. B32B 27/06 (2006.01); B32B 27/18 (2006.01); B32B 27/32 (2006.01); B29C 45/00 (2006.01); B32B 5/18 (2006.01); B29C 44/12 (2006.01); B29C 45/14 (2006.01); B29K 507/04 (2006.01); B29K 23/00 (2006.01); B29K 105/04 (2006.01)
CPC B32B 27/065 (2013.01) [B29C 45/0001 (2013.01); B32B 5/18 (2013.01); B32B 27/18 (2013.01); B32B 27/32 (2013.01); B29C 44/1285 (2013.01); B29C 45/14 (2013.01); B29K 2023/12 (2013.01); B29K 2105/041 (2013.01); B29K 2507/04 (2013.01); B32B 2250/02 (2013.01); B32B 2250/242 (2013.01); B32B 2264/108 (2013.01); B32B 2266/025 (2013.01); B32B 2266/104 (2016.11); B32B 2307/56 (2013.01); B32B 2605/08 (2013.01)] 7 Claims
OG exemplary drawing
 
1. A component comprising:
a composite structure comprising a closed cell foam core, and an overmolded skin disposed on the closed cell foam core,
wherein the closed cell foam core comprises a first polymer-graphene material with between about 0.5 wt. % and about 1.0 wt. % 2D graphene, an average pore size between about 25 μm and about 75 μm, and a cross-section pore density between about 4×106 cells/mm2 and about 6×106 cells/mm2,
wherein the overmolded skin comprises a second polymer-graphene material with between about 0.5 wt. % and about 1.0 wt. % 2D graphene, and
wherein the closed cell foam core weighs at least 5% less than a solid core formed from the first polymer and the composite structure exhibits an increase in energy absorption of at least 50% compared to a closed cell foam core formed from the first polymer without graphene.