U.S. patent application number 09/840932 was filed with the patent office on 2001-11-15 for devices and methods for reinforcing hollow structural members.
Invention is credited to Iwamoto, Katsutoshi, Matsuki, Nobuaki.
Application Number | 20010039780 09/840932 |
Document ID | / |
Family ID | 18635996 |
Filed Date | 2001-11-15 |
United States Patent
Application |
20010039780 |
Kind Code |
A1 |
Matsuki, Nobuaki ; et
al. |
November 15, 2001 |
Devices and methods for reinforcing hollow structural members
Abstract
Reinforcement devices (10, 10', 110, 110') may be inserted into
a cavity (6) of a hollow structural member (1) in order to
reinforce the hollow structural member (1). The reinforcement
devices (10, 10', 110, 110') may include a first elongated
reinforcement part (11, 111) having at least one mating surface
(15a, 17a, 115a) extending along a longitudinal axis of the first
part (11, 111) and a second elongated reinforcement part (12, 121)
having at least one mating surface (25a, 27a, 125a) extending along
a longitudinal axis of the second part (12, 121). An adhesive resin
material preferably adheres the first elongated reinforcement part
(11, 111) to the second elongated reinforcement part (12, 121). The
adhesive resin material may comprise a thermosetting resin that
thermosets when heated. Thus, a thermoset product (31, 136) will
connect the reinforcement parts (11, 12, 111, 121) after heating.
In addition or in the alternative, the adhesive resin material may
comprise a foamable resin that foams when heated. Thus, a foamed
product (31, 136) will connect the reinforcement parts (11, 12,
111, 121) after heating.
Inventors: |
Matsuki, Nobuaki;
(Nisshin-shi, JP) ; Iwamoto, Katsutoshi;
(Okazaki-shi, JP) |
Correspondence
Address: |
DENNISON, SCHEINER SCHULTZ & WAKEMAN
612 CRYSTAL SQUARE FOUR
1745 JEFFERSON DAVIS HIGHWAY
ARLINGTON
VA
22202-3417
US
|
Family ID: |
18635996 |
Appl. No.: |
09/840932 |
Filed: |
April 25, 2001 |
Current U.S.
Class: |
52/742.1 ;
428/139; 428/140; 52/834 |
Current CPC
Class: |
Y10T 428/24347 20150115;
B62D 29/04 20130101; Y10T 428/24339 20150115 |
Class at
Publication: |
52/742.1 ;
52/738.1; 52/740.1; 52/740.3; 52/740.4 |
International
Class: |
E04C 003/30; E04B
001/00; E04G 021/00; E04G 023/00 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 26, 2000 |
JP |
2000-126169 |
Claims
What is claimed is:
1. An apparatus adapted to be inserted into a cavity of a hollow
structural member and to reinforce the hollow structural member,
comprising: a first elongated reinforcement part having at least
one mating surface extending along a longitudinal axis of the first
elongated reinforcement part, a second elongated reinforcement part
having at least one mating surface extending along a longitudinal
axis of the second elongated reinforcement part and an adhesive
resin material adhering the first elongated reinforcement part to
the second elongated reinforcement part.
2. An apparatus as defined in claim 1, wherein the adhesive resin
material comprises an elongated connecting rod disposed between the
mating surface of the first elongated reinforcement part and the
mating surface of the second elongated reinforcement part.
3. An apparatus as defined in claim 1, wherein the first elongated
reinforcement part further comprises at least one flange extending
along the longitudinal axis of the first elongated reinforcement
part, the second elongated reinforcement part further comprises at
least one flange extending along the longitudinal axis of the
second elongated reinforcement part and the adhesive resin material
comprises a fastener coupling the flanges.
4. An apparatus as defined in claim 3, wherein the adhesive resin
material further comprises an elongated connecting rod disposed
between the mating surface of the first elongated reinforcement
part and the mating surface of the second elongated reinforcement
part.
5. An apparatus as defined in claim 4, wherein the fastener is a
clip.
6. An apparatus as defined in claim 5, wherein the adhesive resin
material comprises a thermosetting resin that thermosets when
heated, wherein the first and second reinforcement parts will be
connected by a thermoset product after heating.
7. An apparatus as defined in claim 5, wherein the adhesive resin
material comprises a foamable resin that foams when heated.
8. An apparatus as defined in claim 5, wherein the adhesive resin
material comprises a foamable, thermosetting resin that thermosets
and foams when heated, wherein the reinforcement parts will be
connected by a foamed, thermoset product after heating.
9. An apparatus as defined in claim 8, wherein at least one of the
first elongated reinforcement part or the second reinforcement part
comprises a synthetic resinous material.
10. An apparatus as defined in claim 9, wherein at least one of the
first elongated reinforcement part or the second reinforcement part
is a substantially light-weight hollow part that comprises at least
one supplemental wall constructed to impart strength and rigidity
to the first or second reinforcement part.
11. An apparatus as defined in claim 1, wherein the adhesive resin
material comprises a thermosetting resin that thermosets when
heated.
12. An apparatus as defined in claim 1, wherein the adhesive resin
material comprises a foamable resin that foams when heated, wherein
the reinforcement parts will be connected by a foamed product after
heating.
13. An apparatus as defined in claim 1, wherein the adhesive resin
material comprises a foamable, thermosetting resin that thermosets
and foams when heated, wherein the reinforcement parts will be
connected by a foamed, thermoset product after heating.
14. An apparatus as defined in claim 13, wherein at least one of
the first elongated reinforcement part or the second reinforcement
part comprises a synthetic resinous material.
15. An apparatus as defined in claim 13, wherein at least one of
the first elongated reinforcement part or the second reinforcement
part is a substantially light-weight hollow part that comprises at
least one supplemental wall constructed to impart strength and
rigidity to the first or second reinforcement part.
16. An apparatus as in claim 13, wherein the adhesive resin
material has been heated to form the foamed, thermoset product.
17. An apparatus as defined in claim 1, wherein the first elongated
reinforcement part comprises at least two mating surfaces extending
along the longitudinal axis of the first elongated reinforcement
part, the second elongated reinforcement part comprises at least
two mating surfaces extending along the longitudinal axis of the
second elongated reinforcement part and the adhesive resin material
comprises at least two elongated connecting rod disposed between
the respective mating surfaces of the first elongated reinforcement
part and the respective mating surfaces of the second elongated
reinforcement part.
18. An apparatus as defined in claim 1, wherein the adhesive resin
material comprises an epoxy resin, a urethane or a phenol
resin.
19. An apparatus as defined in claim 1, wherein the adhesive resin
material comprises (i) a co-polymer of epichlorohydrin and
bisphenol A, (ii) a composition comprising phenol and formaldehyde,
(iii) a composition comprising isocyanate and an alcohol or (iv) a
composition comprising maleic anhydride, fumaric acid and
glycol.
20. An apparatus as defined in claim 1, wherein at least one of the
first elongated reinforcement part or the second reinforcement part
comprises a synthetic resinous material and at least one of the
first elongated reinforcement part or the second reinforcement part
is a substantially light-weight hollow part that comprises at least
one supplemental wall constructed to impart strength and rigidity
to the first or second reinforcement part, wherein at least one of
the mating surfaces comprises grooves having an opening
circumference that is less than an interior circumference, the
adhesive resin material comprises a thermosetting, foamable resin,
wherein a thermoset, foamed product is formed during the heating
step and the thermoset, foamed product securely bonds the first and
second reinforcement parts together by engaging a lip defined
within the grooves and securely fits the first and second
reinforcement parts within the cavity.
21. A method for reinforcing a hollow structural member,
comprising: adhering at least two elongated reinforcement parts
using an adhesive resin material, thereby forming an intermediate
reinforcement device, disposing the intermediate reinforcement
device within a cavity defined within the hollow structural member
and applying external heat to the reinforcement device.
22. A method as defined in claim 21, wherein the adhesive resin
material comprises a thermosetting resin, wherein a thermoset
product is formed during the heating step and the thermset product
securely bonds the at least two reinforcement parts.
23. A method as defined in claim 21, wherein the adhesive resin
material comprises a foamable resin, wherein a foamed product is
formed during the heating step and the foamed product securely fits
the at least two reinforcement products within the cavity.
24. A method as defined in claim 21, wherein the adhesive resin
material comprises a thermosetting, foamable resin, wherein a
thermoset, foamed product is formed during the heating step and the
thermoset, foamed product securely bonds the at least two
reinforcement parts together and securely fits the at least two
reinforcement products within the cavity.
25. A method as defined in claim 21, wherein the adhesive resin
material comprises an epoxy resin, a urethane or a phenol
resin.
26. A method as defined in claim 21, wherein the adhesive resin
material comprises (i) a co-polymer of epichlorohydrin and
bisphenol A, (ii) a composition comprising phenol and formaldehyde,
(iii) a composition comprising isocyanate and an alcohol or (iv) a
composition comprising maleic anhydride, fumaric acid and
glycol.
27. A method as defined in claim 21, wherein the at least two
elongated reinforcement parts each comprise at least one flange
extending along a longitudinal axis of the elongated reinforcement
part and the adhesive resin material comprises a fastener coupling
the flanges.
28. A method as defined in claim 27, wherein the at least two
elongated reinforcement parts each comprise at least mating surface
extending along a longitudinal axis of the elongated reinforcement
part, wherein the adhesive resin material further comprises an
elongated connecting rod disposed between the mating surfaces of
the at least two elongated reinforcement parts.
29. A method as defined in claim 28, wherein the fastener is a
clip.
30. A method as defined in claim 29, wherein at least one of the
mating surfaces comprises grooves having an opening circumference
that is less than an interior circumference, the adhesive resin
material comprises a thermosetting, foamable resin, wherein a
thermoset, foamed product is formed during the heating step and the
thermoset, foamed product securely bonds the at least two
reinforcement parts together by engaging a lip defined within the
grooves and securely fits the at least two reinforcement parts
within the cavity.
31. A method as defined in claim 21, wherein the at least two
elongated reinforcement parts each comprise at least mating surface
extending along a longitudinal axis of the elongated reinforcement
part, wherein the adhesive resin material comprises an elongated
connecting rod disposed between the mating surfaces of the at least
two elongated reinforcement parts.
32. A method as defined in claim 31, wherein the adhesive resin
material comprises a thermosetting, foamable resin and wherein a
thermoset, foamed product is formed during the heating step and the
thermoset, foamed product securely bonds the at least two
reinforcement parts together and securely fits the at least two
reinforcement products within the cavity.
33. A method as defined in claim 32, wherein at least one elongated
reinforcement part comprises a synthetic resinous material.
34. A method as defined in claim 33, wherein at least one elongated
reinforcement part is a substantially light-weight hollow part that
comprises at least one supplemental wall constructed to impart
strength and rigidity to the at least one elongated reinforcement
part.
35. An apparatus (10, 10', 110, 110') disposed within a cavity (6)
of a hollow structural member (1) in order to reinforce the hollow
structural member (1) comprising: a first elongated reinforcement
part (11, 111) having at least one mating surface (15a, 17a, 115a)
extending along a longitudinal axis of the first part (11, 111), a
second elongated reinforcement part (21, 121) having at least one
mating surface (25a, 27a, 125a) extending along a longitudinal axis
of the second part (21, 121), wherein at least one of the first
elongated reinforcement part (11, 111) or the second reinforcement
part (12, 121) comprises a synthetic resinous material and wherein
at least one of the first elongated reinforcement part (11, 111) or
the second reinforcement part (21, 121) is a substantially
light-weight hollow part that comprises at least one supplemental
wall (15, 25, 115, 125) constructed to impart strength and rigidity
to the part (11, 21, 111, 121) and at least one elongated
connecting rod (30, 130) adhering the mating surface (15a, 17a,
115a) extending along the longitudinal axis of the first elongated
reinforcement part (11, 111) to the mating surface (25a, 27a, 125a)
extending along the longitudinal axis of the second elongated
reinforcement part (21, 121), wherein the at least one elongated
connecting rod (30, 130) comprises a thermosetting, foamable resin
and wherein a thermoset, foamed product is formed upon heating and
the thermoset, foamed product will bonds the first elongated
reinforcement part (11, 111) to the second elongated reinforcement
part (21, 121) and will fit the first elongated reinforcement part
(11, 111) and the second elongated reinforcement part (21, 121)
within the cavity (6).
36. An apparatus as in claim 35, wherein the mating surface (15a,
17a, 115a) extending along the longitudinal axis of the first
elongated reinforcement part (11, 111) and the mating surface (25a,
27a, 125a) extending along the longitudinal axis of the second
elongated reinforcement part (21, 121) each comprise grooves (13,
23) having an opening circumference that is less than an interior
circumference, wherein the thermoset, foamable product will engage
a lip (23a) defined within the grooves (13, 23).
37. An apparatus as in claim 36, wherein the mating surfaces (15a,
17a, 25a, 27a, 115a, 125a) are roughened.
38. An apparatus as defined in claim 37, wherein the first
elongated reinforcement part (111) further comprises at least one
flange (116) extending along the longitudinal axis of the first
part (111), the second elongated reinforcement part (121) further
comprises at least one flange (126) extending along the
longitudinal axis of the second part (121) and a fastener (132,
135) couples the flanges (116, 126).
39. An apparatus as defined in claim 38, wherein the fastener
comprises a thermosetting, foamable resin.
40. A apparatus as defined in claim 39, wherein the adhesive resin
material comprises (i) a co-polymer of epichlorohydrin and
bisphenol A, (ii) a composition comprising phenol and formaldehyde,
(iii) a composition comprising isocyanate and an alcohol or (iv) a
composition comprising maleic anhydride, fumaric acid and glycol.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to devices and structures for
reinforcing a hollow structural member. More particularly, the
present invention relates to devices and structures for reinforcing
a closed box-like hollow structural member constructed from two or
more plates, such as a front pillar, a center pillar, a quarter
pillar, a roof side panel or a rocker panel of a vehicle.
Preferably, the reinforcing device increases the strength and
rigidity of the hollow structural member.
[0003] 2. Description of the Related Art
[0004] In order to reinforce a hollow structural member (for
example, a front pillar of a vehicle), a reinforcement device may
be disposed within a cavity of the hollow structural member. Such a
reinforcement device may be an elongated member that is arranged
within the cavity in such a way as to extend along a longitudinal
direction of the hollow structural member. A known reinforcement
device is taught, for example, by Japanese Laid-open Patent
Publication Number 10-53156.
[0005] Reinforcement devices are also known that are integrally
formed by injection molding, extrusion molding, blow molding or
other such processes, so as to have lightweight and high rigidity.
However, it is difficult to integrally form the reinforcement
device if the device has a complicated longitudinal cross-sectional
configuration or if the device has a transverse cross-sectional
shape that changes along the longitudinal direction of the hollow
structural member. For example, the reinforcement device may be
substantially hollow, so that the reinforcement device is
lightweight. However, support structures may be provided within the
hollow portion in order to impart rigidity and strength to the
reinforcement device. In the known art, such reinforcement devices
are constructed from a plurality of reinforcement device parts that
are separately manufactured. After separately forming the
individual reinforcement device parts, these parts are joined or
attached by screws, mechanical fasteners or welding. However, such
a construction can be labor intensive and costly.
SUMMARY OF THE INVENTION
[0006] It is, accordingly, an object of the present teachings to
provide improved reinforcement devices and methods for reinforcing
hollow structural members. Preferably, one or more problems
associated with the known art can be significantly reduced or
eliminated.
[0007] Several reinforcing devices are taught in the present
specification. In one aspect of the present teachings,
reinforcement devices may be constructed for insertion into a
cavity of a hollow structural member. The reinforcement devices may
be substantially hollow and may include one or more structures that
serve to reinforce the hollow structural member in order to impart
strength and rigidity to the hollow structural member. In another
aspect of the present teachings, reinforcement devices may include
at least two elongated reinforcement parts. An adhesive fastener is
preferably disposed between the elongated reinforcement parts in
order to attach the reinforcement parts. In one embodiment of the
present teachings, the adhesive fastener essentially comprises one
or more adhesive thermosetting resins that will thermoset when
heated. Thus, the reinforcement device may include the
reinforcement parts that are connected by a thermoset adhesive
product. In another embodiment of the present teachings, the
adhesive fastener also may have the property of foaming or
expanding when heated. In this embodiment, the adhesive fastener
also may have the desirable effect of securing the reinforcement
device within the hollow structural member after heating due to the
expansion of the adhesive fastener.
[0008] In another aspect of the present teachings, several methods
are taught for reinforcing a hollow structural member. In another
embodiment of the present teachings, the methods may include
attaching at least two elongated reinforcement parts using an
adhesive fastener in order to form a reinforcement device. In a
further preferred embodiment, the adhesive fastener may essentially
comprise one or more adhesive thermosetting resins. In another
embodiment of the present teachings, the reinforcement device may
be disposed within a cavity of the hollow structural member and
then external heat may be applied to the adhesive fastener in order
to produce a thermoset product. Consequently, the thermoset product
will securely bind the reinforcement parts. In another embodiment
of the present teachings, the adhesive fastener also may foam or
expand when heated, which may have the desirable effect of securing
the reinforcement device within the hollow structural member. In
each of these methods, the reinforcement devices may be
substantially hollow and may include one or more structures that
serve to reinforce the hollow structural member in order to impart
strength and rigidity to the hollow structural member.
[0009] According to the present teachings, two or more elongated
reinforcement parts may be attached or bonded by a thermoset
product that is produced from an adhesive fastener. That is, the
reinforcement parts can be securely bonded by simply heating the
adhesive fastener to produce the thermoset product. Therefore, the
reinforcement device can be easily and speedily produced. Further,
in another aspect of the present teachings, the reinforcement
device may impart rigidity and strength to the hollow structural
member.
[0010] The present teachings will become more fully apparent from
the following description and claims as it proceeds in connection
with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view of a reinforcement device that
is designed to reinforce a hollow structural member according to a
first representative embodiment of the present teachings before a
first reinforcement part is attached or bonded to a second
reinforcement part;
[0012] FIG. 2(A) is an explanatory view of the reinforcement device
of FIG. 1, which view illustrates the relative positions of the
first and second reinforcement parts before being coupled using
adhesive connecting rods;
[0013] FIG. 2(B) is an explanatory view similar to FIG. 2(A), which
view illustrates the relative positions of the first and second
reinforcement parts before being coupled using adhesive connecting
rods;
[0014] FIG. 3 is a side view of the reinforcement device of FIG.
2(B) positioned within the hollow structural member;
[0015] FIG. 4 is a cross-sectional view taken along line IV-IV in
FIG. 3;
[0016] FIG. 5 is a cross-sectional view similar to FIG. 4 after the
adhesive connecting rods have been expanded or foamed;
[0017] FIG. 6(A) is an enlarged fragmentary cross-sectional view of
the reinforcement device according to a modification of the first
representative embodiment before the adhesive connecting rods have
been expanded or foamed;
[0018] FIG. 6(B) is a cross-sectional view similar to FIG. 6(A)
after the connecting rods have been expanded or foamed;
[0019] FIG. 7 is a cross-sectional view of a reinforcement device
according to a second representative embodiment of the present
teachings;
[0020] FIG. 8(A) is an enlarged fragmentary cross-sectional view of
a reinforcement device according to a modification of the second
representative embodiment before the fasteners have been expanded
or foamed; and
[0021] FIG. 8(B) is a cross-sectional view similar to FIG. 8(A)
after the fasteners have been expanded or foamed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Preferred embodiments of the invention will now be described
in detail with reference to the drawings.
[0023] A first detailed representative embodiment is shown in FIGS.
1 to 5. As shown in FIGS. 3-5, a pillar 1 of a vehicle body is
exemplified as a hollow structural member. For example, the pillar
1 may be a center pillar or a front pillar of a vehicle body,
although naturally a variety of hollow structural members are
contemplated by the present teachings. As best shown in FIGS. 4 and
5, the pillar 1 is constructed from an elongated inner pillar panel
2, which has flanges 3 extending along the edges of the panel 2,
and an elongated outer pillar panel 4, which has flanges 5
extending along the edges of the panel 4. The inner pillar panel 2
and outer pillar panel 4 preferably are spot welded along flanges 3
and 5, although other attaching methods and means may be utilized.
Thus, the pillar 1 has an elongated closed box-like hollow shape
and a longitudinally extending cavity 6 is defined within pillar
1.
[0024] The cavity 6 preferably is constructed to receive an
elongated reinforcement device 10 or an intermediate reinforcement
device 10' that extends along the longitudinal direction of the
pillar 1. The reinforcement device 10, 10' preferably reinforces
the pillar 1 in order to provide strength and rigidity to the
pillar 1. As best shown in FIG. 1, the reinforcement device 10 (or
the intermediate reinforcement device 10') may include, for
example, a U-shaped first or lower reinforcement device part 11
that has side walls 17 and a bottom wall 18. A U-shaped second or
upper reinforcement device part 21 also may be provided and also
may have side walls 27 and a bottom wall 28. Each of the first part
11 and the second part 21 preferably has a supplemental wall 15,
25, respectively. Preferably, the supplemental walls 15, 25
longitudinally extend along the respective bottom walls 18, 28. The
supplemental walls 15, 25 are preferably designed to impart
strength and rigidity to the parts 11, 21 without adding a
significant amount of weight. Thus, the interior portions of parts
11, 21 may be substantially hollow in order to minimize the weight
of the reinforcement device 10, 10'. In this embodiment, the
supplemental walls 15, 25 have a substantially triangular
cross-section when viewed with the respective bottom walls 18, 28,
although the supplemental walls 15, 25 may have other shapes that
impart strength and rigidity to the parts 11, 21.
[0025] Parts 11, 21 preferably are integrally formed from heat
resistive hard synthetic resinous materials. Known techniques may
be utilized to manufacture parts 11, 21, such as injection molding,
extrusion molding, blow molding or other such processes.
Preferably, the outer dimensions of the parts 11, 21 are designed
to substantially correspond to the interior dimensions of the
cavity 6. While parts 11, 21 both preferably comprise a resinous
material, one (or both) of parts 11, 21 may comprise a metal, such
as light metals or their alloys, for example, aluminum alloys. In
addition, the parts 11, 21 can be formed from different types of
metals that cannot be easily be welded to each other, if desired,
because the parts 11, 21 will be connected by an adhesive fastener
to form the reinforcement device 10, 10'.
[0026] End surfaces 17a, 27a, 15a, 25a, i.e. mating surfaces, are
formed on the respective side walls 17, 27 and the supplemental
walls 15, 25. Preferably, the first and second reinforcement parts
11, 21 are designed so that the side wall end surfaces 17a and the
supplemental wall end surfaces 15a face the corresponding side wall
end surfaces 27a and the corresponding supplemental wall end
surfaces 25a. Thus, when the respective end surfaces 17a, 27a, 15a,
25a are disposed so as to face each other, connecting portions are
defined between the respective end surfaces 17a, 27a, 15a, 25a. In
addition, the first and second parts 11, 21 preferably are
symmetrically designed. That is, parts 11, 21 preferably have the
same three-dimensional configuration in cross-section. As a result,
the manufacturing costs of these parts 11, 21 can be reduced,
because the parts 11, 21 can be manufactured by utilizing a common
molding die. However, parts 11, 21 also may naturally have
non-symmetrical configurations.
[0027] The first reinforcement part 11 and the second reinforcement
part 21 are temporarily attached or bonded to each other by an
adhesive fastener, such as connecting rods 30 in this
representative embodiment. Connecting rods 30 are preferably
elongated structures and are disposed along the connecting portions
between the end surfaces 17a, 15a and the corresponding end
surfaces 27a, 25a. By temporarily attaching or bonding parts 11, 21
using connecting rods 30, an intermediate reinforcement device 10'
is formed. Preferably, the connecting rods 30 comprise an adhesive
composition that can securely couple the parts 11, 21. In another
preferred embodiment, the connecting rods 30 comprise an adhesive
resin material that thermosets upon heating in order to more
securely bond the parts 11, 21. Herein, a thermosetting adhesive
resin material is intended to mean any polymer that softens when
initially heated and then hardens and condenses in bulk in order to
retain a permanent shape. Generally speaking, thermosetting
adhesive resin materials can not be softened or reprocessed by
reheating. In a still further embodiment, the adhesive resin
material preferably comprises a foamable material and the foamable
material can be expanded or foamable by heating in order to produce
a thermoset product 31. Thus, in one embodiment, the connecting
rods 30 are heated after being disposed between parts 11, 21 in
order to change the connecting rods 30 into the thermoset products
31 and thereby produce the reinforcement device 10.
[0028] Thus, adhesive resin of connecting rods 30 preferably has
the property of adhering the parts 11, 21 without heating. In
another aspect of the present teachings, the adhesive resin can be
thermoset by heating in order to more securely adhere the parts 11,
21. In a further aspect of the present teachings, the adhesive
resins also preferably are capable of foaming and expanded upon
heating. If all three properties are utilized together, the
connecting rods 30 may be foamed and thermoset upon heating,
although adhesive resins exhibiting only one or two of the
above-noted properties also may be utilized with the present
teachings. Representative examples of preferred adhesive resins
include, but are not limited to, epoxy resins, urethanes or other
esters, phenol resins and other similar adhesive resin materials.
More preferably, the adhesive resin materials of the present
teachings may include (i) a co-polymer of epichlorohydrin and
bisphenol A (an epoxy resin), (ii) a composition comprising phenol
and formaldehyde (a phenolic resin), (iii) a composition comprising
isocyanate and an alcohol (a polyurethane resin) and (iv) a
composition comprising maleic anhydride, fumaric acid and glycol
(an unsaturated polyester resin). The reinforcement device 10, 10'
can be heated (for example, 110.degree. C.-190.degree. C.) using,
e.g. an oven, for about 10-60 minutes in order to thermoset and/or
foam the adhesive resin material. This heat treatment may also
advantageously bake any coating materials that have been disposed
on the pillar 1 and/or the vehicle body in order to impart
corrosion resistance to the pillar 1 and/or vehicle body.
[0029] Representative methods for reinforcing the pillar 1 using
the representative reinforcement device 10, 10' will now be
described. In a first or preparation step, as shown in FIG. 1, the
first and second reinforcement parts 11, 21 of the reinforcement
device 10 are separately manufactured and comprise one or more heat
resistive hard synthetic resinous materials. For example, if parts
11, 21 are symmetrical, a common molding die may be preferably
utilized. Further, the adhesive connecting rods 30 are manufactured
from an adhesive resin material for example by extrusion molding.
In one embodiment of the present teachings, the connecting rods 30
have substantially the same length as the reinforcement parts 11,
21. In a second or assembling step, as shown in FIGS. 2(A) and
2(B), the first and second reinforcement parts 11, 21 are disposed
opposite of each in such a way that the side wall end surfaces 17a
and the supplemental wall end surface 15a of the part 11 face the
corresponding side wall end surfaces 27a and the corresponding
supplemental wall end surface 25a of the part 21. Further, one or
more connecting rods 30 are interleaved between the surfaces 17a,
15a and the corresponding surfaces 27a, 25a. Thereafter, these
reinforcement parts 11, 21 may be pressed together in order to
sandwich the connecting rods 30 between the surfaces 17a, 15a and
the corresponding surfaces 27a, 25a. As a result, the connecting
rods 30 are compressed and deformed. Further, because the
connecting rods 30 have an adhesive property, the surfaces 17a, 15a
will adhere to the surfaces 27a, 25a. Thus, the first and second
reinforcement parts 11, 21 are attached and form the intermediate
reinforcement device 10'.
[0030] In a third or mounting step, as shown in FIGS. 3 and 4, the
intermediate reinforcement device 10' is longitudinally positioned
on the inner plate 2 of the pillar 1. A pair of support plates 40
may be utilized to clamp or hold the reinforcement device 10' in
position. However, other types of support or attaching members may
be utilized to position the reinforcement device 10' within cavity
6, including for example clamps, fasteners, adhesives, clips,
screws, etc. All such support or attaching members arc considered
to be attaching means within the present teachings. Thereafter, the
inner panel 2 and the outer panels 4 are preferably welded along
flanges 3 and 5 to thereby form the pillar 1. As a result, the
intermediate reinforcement device 10' is appropriately arranged
within the cavity 6 of the pillar 1.
[0031] Subsequently, in a fourth or heating step, the vehicle body
having the pillar 1 typically is heated (e.g. using an oven) to
bake any coating materials disposed on the pillar 1 and/or vehicle
body. As a result, the intermediate reinforcement device 10'
disposed within the cavity 6 will also be heated. If the connecting
rods 30 comprise an adhesive resin material that thermosets upon
heating, the connecting rods 30 will thermoset and securely adhere
the parts 11, 21. If the connecting rods 30 comprise an adhesive
resin material that foams or expands upon heating, the connecting
rods 30 will expand during the heating step. Further, if the
connecting rods 30 are capable of both thermosetting and foaming,
foamed and thermoset connecting products 31 will be produced
between the surfaces 17a, 15a and the corresponding surfaces 27a,
25a. As shown in FIG. 5, the first and second reinforcement parts
11, 21 may be securely attached or bonded by the connecting
products 31, thereby producing the integral reinforcement device
10. As a result, the reinforcement device 10 may impart rigidity
and strength to the pillar 1. In addition, the outer surface of
reinforcement device 10 may tightly contact the inner surface of
the cavity 6, if the connecting rod 30 expand or foam during the
heating step. By tightly contacting the surface of the cavity 6,
the reinforcement device 10 may impart further strength and
rigidity to the pillar 1.
[0032] According to the first representative embodiment, the
reinforcement device 10 can be produced by simply heating the
pillar 1 after the intermediate reinforcement device 10' is
introduced into the pillar cavity 6. Further, the intermediate
reinforcement device 10' can be produced by simply pressing
together the reinforcement parts 11, 21 with the adhesive
connecting rods 30 disposed between the parts 11, 21. Therefore,
the reinforcement device 10 can be easily and quickly manufactured
without using additional connecting means. Further, although the
first and second parts 11, 21 arc symmetrically shaped in the first
representative embodiment, the parts 11, 21 may be asymmetrically
shaped, if desired. In addition, the cross-section of each of the
parts 11, 21 may change along the longitudinal axis of the parts
11, 21. Thus, the parts 11, 21 are not required to have a uniform
cross section along the entire length of the parts 11, 21.
[0033] Further, the mating surfaces 17a, 15a, 27a, 25a of the first
and second parts 11, 21 can be roughened in order to increase the
bonding strength between first and second parts 11, 21. In another
embodiment of the present teachings, as shown in FIGS. 6(A) and
6(B), each of the surfaces 17a, 15a, 27a, 25a of the parts 11, 21
may have dovetail grooves 13, 23. Thus, if the connecting rods 30
are capable of foaming, the foamed connecting products 31 will
partially enter into the grooves 13, 23, to thereby further
increase the bonding strength between first and second parts 11,
21. The grooves 13, 23 may also be any type of groove that is
characterized by having an opening diameter or circumference that
is less than an interior diameter circumference. For example,
grooves 13, 23 may also have a rounded shape or other interior
shape. Thus, an inner lip or edge 23a of the groove 13, 23 is
formed because the opening diameter or circumference is narrower
than at least a portion of the interior diameter or circumference.
Consequently, the inner lip or edge 23a may serve to retain the
foamed product 31 and more reliably bond parts 11, 21.
[0034] As noted above, the connecting rods 30 also may comprise
thermosetting resins that do not contain foamable materials, if
desired. In such case, the connecting rods 30 will melt and
thermoset, to thereby produce solid connecting products 31. Even
though connecting rods 30 do not expand, the first and second
reinforcement parts 11, 21 can still be securely adhered by the
connecting products 31. Furthermore, the mating surfaces 17a, 15a,
27a, 25a of the parts 11, 21 may optionally include one or more
longitudinally extending recesses (not shown) that serve to retain
or position the connecting rods 30 before the parts 11, 21 are
pressed together.
[0035] A second detailed representative embodiment of the present
teachings is shown in FIG. 7 and the second detailed representative
embodiment is related to the first detailed representative
embodiment. Therefore, it is only necessary to describe
constructions of the second detailed representative embodiment that
are different from constructions described in the first detailed
representative embodiment.
[0036] As shown in FIG. 7, a reinforcement device 110 or an
intermediate reinforcement device 110' may include a first or lower
reinforcement device part 111 that has side walls 117 and a second
or upper reinforcement device part 121 that has side walls 127 The
first part 111 preferably has supplemental walls 115 and the second
part 121 also preferably has supplemental walls 125.
[0037] The side walls 117, 127 may also include respective
engagement projections or outward flanges 116, 126. For example,
the flanges 116, 126 may be preferably constructed to adjoin each
other when the first and second parts 111, 121 are placed together.
Moreover, similar to the supplemental walls 15, 25 of the first
representative embodiment, the supplemental walls 115, 125 also
have respective end surfaces 115a, 125a, which may serve as mating
surfaces when the first and second parts 111, 121 are placed
together.
[0038] The second representative embodiment may further include a
pair of fasteners or clamping members 132. Optionally, the clamping
members 132 may comprise the same adhesive resin as the connecting
rod 130, although naturally the clamping members 132 may comprise a
different material. The clamping members 132 may each have a
symmetrical U-shape in transverse cross section, so as to tightly
fit along the adjoining flanges 116, 126. The clamping members 132
preferably are formed by injection molding, extrusion molding, blow
molding or other such processes.
[0039] Representative methods for reinforcing the pillar 1 using
the representative reinforcement device 110, 110' will now be
described. In a preparation step, the first and second
reinforcement parts 111, 121, the clamping members 132 and the
connecting rod 130 are manufactured. In an assembling step, the
first and second reinforcement parts 111, 121 are oppositely
arranged in such a way that the flanges 116 and the supplemental
wall end surfaces 115a of the part 111 face the respective flanges
126 and the supplemental wall end surface 25a of the part 121.
Preferably, the connecting rod 130 is disposed or interleaved
between the supplemental wall surfaces 115a, 125a. Thereafter,
these reinforcement parts 111, 121 are pressed together and the
connecting rod 130 is sandwiched between the surfaces 115a, 125a.
Further, the flanges 116, 126 will be disposed to closely adjoin
each other. Subsequently, the clamping members 132 are fitted onto
the adjoined flanges 116, 126. As a result, the flanges 116, 126
are securely clamped, and the adhesive connecting rod 130 is
compressed and deformed, so as to adhere the mating surfaces 115a
and 125a. Thus, the first and second reinforcement parts 111, 121
are attached to each other to thereby form the intermediate
reinforcement device 110'.
[0040] In a subsequent step, the intermediate reinforcement device
110' is disposed within a hollow structural member (e.g. pillar 1)
and then heated in the same manner as the first representative
embodiment. If the clamping members 132 and the connecting rod 130
are capable of thermosetting, thermoset clamping products and
connecting products (not shown) will be produced. If the clamping
members 132 and the connecting rod 130 are capable of foaming,
foamed clamping products and connecting products (not shown) will
be produced. Naturally, if the clamping members 132 and the
connecting rod 130 are capable of thermosetting and foaming,
thermoset and foamed clamping products and connecting products (not
shown) will be produced. The same types of adhesive connecting rods
30 described with respect to the first representative embodiment
may also be advantageously utilized in the second representative
embodiment. Thus, the first and second reinforcement parts 111, 121
may be securely bonded by these products, to thereby produce the
integral reinforcement device 110. Similar to the first
representative embodiment, the reinforcement device 110 may impart
rigidity and strength to the hollow structural member (e.g. pillar
1).
[0041] Although the connecting rod 130 is interleaved between the
supplemental end wall surfaces 115a, 125a in the second
representative embodiment, the connecting rod 130 can be omitted,
if desired.
[0042] Also, as shown in FIG. 8(A), the clamping members 132 can be
replaced with another type of fastener, such as clips 135.
Moreover, clips 135 may comprise the same adhesive resin material
as the connecting rod 130, although naturally clips 135 may
comprise other materials. The clips 135 are preferably constructed
to engage corresponding apertures 137 that are previously formed in
the flanges 116, 126. As shown in FIG. 8(B), if the clips 135
comprise a thermosetting and foamable resin material, the clips 135
will expand and thermoset when heated and thereby produce foamed
products 136 that close the apertures 137. Thus, the first and
second reinforcement parts 111, 121 may be optionally adhered
together by the foamed products 136.
[0043] Representative examples of the present invention have been
described in detail with reference to the attached drawings. This
detailed description is merely intended to teach a person of skill
in the art further details for practicing preferred aspects of the
present teachings and is not intended to limit the scope of the
invention. Only the claims define the scope of the claimed
invention. Therefore, combinations of features and steps disclosed
in the foregoing detail description may not be necessary to
practice the invention in the broadest sense, and are instead
taught merely to particularly describe detailed representative
examples of the invention. Moreover, the various features taught in
this specification may be combined in ways that are not
specifically enumerated in order to obtain additional useful
embodiments of the present teachings.
[0044] For example, although the reinforcement members comprise two
reinforcement parts in the first and second representative
embodiments, the present teachings are applicable to reinforcement
members that comprises three or more parts. Further, the pillar of
a vehicle body has been described as a representative hollow
structural member. However, the hollow structural member is not
limited to such pillars and may be a rocker panel, a roof side
panel or other panels of a vehicle body. Moreover, the hollow
structural member is not limited to parts of a vehicle body, as the
present teachings are equally applicable to the reinforcement of
any hollow structural members, such as for example structural
components for buildings and ships.
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