U.S. patent application number 10/649139 was filed with the patent office on 2004-02-26 for vibrational reduction system for automotive vehicles.
This patent application is currently assigned to L&L Products, Inc.. Invention is credited to Kleino, Thomas D..
Application Number | 20040036317 10/649139 |
Document ID | / |
Family ID | 26919324 |
Filed Date | 2004-02-26 |
United States Patent
Application |
20040036317 |
Kind Code |
A1 |
Kleino, Thomas D. |
February 26, 2004 |
Vibrational reduction system for automotive vehicles
Abstract
A vibration reduction and damping system for use in automotive
closure panels, such as doors, lift gates, or other operable
hatches comprising an intrusion device and an expandable material,
such as a polymer-based foam, disposed along at lease a surface of
the intrusion device prior to final assembly of the vehicle by the
vehicle manufacturer. The system is activated as the vehicle
undergoes the final vehicle assembly process, which activates and
transforms the expandable material, preferably during an automobile
paint operation, to expand, bond and fill the door assembly
structure for vibrational damping and noise reduction.
Inventors: |
Kleino, Thomas D.;
(Rochester Hills, MI) |
Correspondence
Address: |
DOBRUSIN & THENNISCH PC
401 S OLD WOODWARD AVE
SUITE 311
BIRMINGHAM
MI
48009
US
|
Assignee: |
L&L Products, Inc.
Romeo
MI
|
Family ID: |
26919324 |
Appl. No.: |
10/649139 |
Filed: |
August 27, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10649139 |
Aug 27, 2003 |
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09858939 |
May 16, 2001 |
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6634698 |
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60225126 |
Aug 14, 2000 |
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Current U.S.
Class: |
296/146.6 ;
296/1.03 |
Current CPC
Class: |
B29C 44/18 20130101;
B60R 13/0892 20130101; B60J 5/0443 20130101 |
Class at
Publication: |
296/146.6 ;
296/1.03 |
International
Class: |
B60J 005/00 |
Claims
What is claimed is:
1. A system for the absorption of vibration in an automotive
closure panel assembly, comprising: (a) an intrusion device
associated with an automotive exterior panel structure; and (b) an
expandable material for absorbing vibration disposed over at least
a portion of said intrusion device and in contact with said
intrusion device prior to expansion of said expandable material,
and with a surface of said panel after expansion of said expandable
material.
2. The system as claimed in claim 1, wherein said intrusion device
has a first end and a second end fixedly attached to an inner
portion of said automotive panel structure thereby defining a
cavity.
3. The system as claimed in claim 1, wherein an external surface of
said intrusion device is at least partially coated with said
expandable material.
4. The system as claimed in claim 1, wherein said expandable
material is a heat activated thermoplastic foamable material.
5. The system as claimed in claim 4, wherein said expandable
material comprises an extruded pellet.
6. The system as claimed in claim 1, wherein said intrusion device
comprises a door intrusion beam having an exposed surface.
7. The system as claimed in claim 6, wherein said exposed surface
of said door intrusion beam is suitable for application of said
expandable material.
8. The system as claimed in claim 1, wherein said intrusion device
is comprised of a high strength polymeric material.
9. The system as claimed in claim 1, wherein said expandable
material is a heat activated expandable polymer foam.
10. The system as claimed in claim 1, wherein said expandable
material is an expandable ethylene based foam that is generally
free of tack to the touch.
11. The system as claimed in claim 9, wherein said expandable
material is an expandable ethylene based foam that can be activated
at a temperature encountered in an automotive vehicle paint
operation.
12. A vibration damping system for a door assembly of an automotive
vehicle, comprising: (a) an intrusion device suitable for fixed
placement within an automotive vehicle having a first end and a
second end mounted to the door assembly defining a cavity therein,
said intrusion device further having exposed surface portions
between said first end and said second end; and (b) a plurality of
nodes of an expandable vibration damping material in bonding
contact over at least a portion of said exposed surface portions of
said intrusion device.
13. The system as claimed in claim 12, wherein said expandable
material is a polymer foam.
14. The system as claimed in claim 12, wherein said intrusion
device is a intrusion device.
15. The system as claimed in claim 12, wherein said expandable
material is a heat activated expandable polymer foam.
16. The system as claimed in claim 12, wherein said expandable
material is an expandable polymer foam that is generally free of
tack to the touch.
17. The system as claimed in claim 12, wherein said expandable
material is an expandable ethylene-based foam that can be activated
at a temperature encountered in an automotive vehicle paint
operation.
18. The system as claimed in claim 12, wherein said nodes include a
plurality of nodes of different sizes and shape.
19. The system as claimed in claim 16, wherein said expandable
material is extruded into pellets.
20. The system as claimed in claim 16, wherein said expandable
material is encapsulated.
21. A system for reducing vibration in an automotive door assembly,
comprising: (a) a intrusion device fixed mounted within an
automotive door assembly; and (b) an expandable material for
reducing vibration disposed over at least a portion of said
intrusion device and in contact with said intrusion device prior to
expansion of said expandable material.
22. The system as claimed in claim 21, wherein said intrusion
device defines a cavity of an automotive door assembly.
23. The system as claimed in claim 21, wherein said intrusion
device is at least partially coated with said expandable
material.
24. The system as claimed in claim 21, wherein said expandable
material is a heat activated thermoplastic foamable material.
25. The system as claimed in claim 24, wherein said expandable
material comprises an extruded pellet.
26. The system as claimed in claim 21, wherein said intrusion
device includes an exposed surface.
27. The system as claimed in claim 26, wherein said exposed surface
of said intrusion device is suitable for application of said
expandable material.
28. The system as claimed in claim 21, wherein said intrusion
device is an automotive intrusion beam.
29. The system as claimed in claim 21, wherein said expandable
material is a heat activated expandable polymer foam.
30. The system as claimed in claim 21, wherein said expandable
material is an expandable ethylene based foam that is generally
free of tack to the touch.
31. The system as claimed in claim 29, wherein said expandable
material is an expandable ethylene based foam that can be activated
at a temperature encountered in an automotive vehicle paint
operation.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to improved methods
and systems for reducing noise and vibration characteristics in an
automotive vehicle. More particularly, the invention relates to an
anti-vibration damping material or pellet application system
integrated along portions of automotive closure panels, such as
portions of an automotive door frame or other panel assembly used
to facilitate passenger or cargo ingress/egress to the vehicle. The
present invention is applied to selected portions of an automotive
vehicle through extrusion techniques resulting in the reduction of
vibration and the improvement of sound absorption characteristics
of the automotive vehicle.
BACKGROUND OF THE INVENTION
[0002] Traditional automotive panel assembly operations generally
require a specific pre-assembly manufacturing step or process,
which occurs prior to final assembly of the vehicle. Typically for
automotive door assemblies, this step or process involves the
application of chemical compositions to a traditional door
intrusion beam after the beam is shipped to the vehicle
manufacturer from the intrusion device supplier. This process
requires the vehicle manufacturer to allocate tooling and
manufacturing facilities for the intrusion device application at
either a separate stamping facility where the door is assembled or
in the final vehicle assembly plant. One such technique employs the
use of pumpable products applied to the intrusion device in the
form of "wet" compositions, which can remain tacky or may otherwise
be applied to the beam in a non-uniform manner. For instance, one
popular technique utilizes a pumpable product consisting of a
thermally activated polymeric material, which upon heat activation
expands and fills the space defined between the intrusion device
and the outer door panel.
[0003] While these prior art system perform well and are
advantageous in many circumstances, they often require a large
capital investment to integrate the pumpable product into the
chosen manufacturing facility, utilize a large amount of floor
space and maintenance clean-up resources at the stamping facility
or vehicle assembly plant, and require an additional manufacturing
process and labor demand. In turn, the manufacturer is required to
devote both financial and technical resources to develop tooling
for the pumpable product as well as transportation costs, which
adds potential cost and delay, particularly if changes to the
vehicle structure are implemented during the design stages.
[0004] Accordingly, there is need for a simple low cost system that
provides an integrated anti-vibration damping material, in the form
of a "dry" chemical product which can be extruded-in-place within
targeted portions of an automotive panel assembly to reduce
vibration characteristics and which can be employed across a wide
range of different sizes or shapes of cavities found in automotive
vehicles.
SUMMARY OF THE INVENTION
[0005] The present invention is directed to a vibration reduction
system, and particularly one for automotive frame assemblies, such
as (without limitation) vehicle door frame assemblies having a door
intrusion device as well as any other automotive closure panel
assemblies used in sliding doors, lift gates, or other designs used
to facilitate the ingress and egress of passengers and/or cargo to
an automotive vehicle. The system generally employs extrusion
techniques in the form of a mini-applicator technology for
facilitating the application of a dry chemical, anti-vibration
damping material onto the intrusion device and/or other selected
portion of the door frame, such as the belt line reinforcement,
through an extrude-in-place process. It is contemplated that the
material disclosed in the present invention functions as an
anti-vibration dampener when expanded and bonded to the door
intrusion device and optionally the inner and outer body panels,
when the intrusion device, such as a intrusion device (now attached
to the vehicle in the assembly operation), is processed through
paint operations and process cycles typically encountered in a
vehicle assembly plant. In one embodiment, the material is heat
expandable and at least partially fills the cavity by cross-linking
the door intrusion device and the inner and outer door panel during
the painting operation thereby reducing noise and vibration
characteristics of the vehicle as well as producing a more quiet
door assembly when the vehicle door is opened and closed. In
another embodiment, the material is a melt-flow material, and upon
the application of heat will spread over a surface.
[0006] The present invention further serves to eliminate
cleanliness and maintenance issues typically encountered through
the use of a pumpable product process or application of "wet"
chemical technology in either a pre-assembly stamping facility or a
vehicle assembly plant since the anti-vibration damping material
can be extruded or mini-application bonded onto the door intrusion
device prior to paint operation processing. Hence, the present
invention can be utilized by either the door intrusion device
manufacturer or the vehicle manufacturer and extruded onto the door
intrusion device itself for use by the vehicle manufacturer in the
final assembly operation.
[0007] In a particular preferred embodiment, the damping material
or medium comprises a plurality of pellets or a bead that is
extruded along and onto portions of the intrusion device in a solid
(though pliable) form in accordance with the teachings of commonly
owned U.S. Pat. No. 5,358,397 ("Apparatus For Extruding Flowable
Materials"), hereby expressly incorporated by reference, such type
of apparatus being referred to herein as a "min-applicator." A
preferred mini-applicator is an extrude-in-place device suitable
for extrusion with or without robotic assistance, and which may be
portable or remain stationary in a predetermined location. The use
of a mini-applicator advantageously allows extrusion of meltable
plastic materials of various section sizes or shapes directly at
production or assembly lines. The material or medium is at least
partially coated with an active polymer having damping
characteristics or other heat activated polymer, (e.g., a formable
hot melt adhesive based polymer or an expandable structural foam,
examples of which include olefinic polymers, vinyl polymers,
polyamides, EVA's, thermoplastic adhesives, thermoplastic
rubber-containing polymers, epoxies, urethanes or the like). The
pellet then expands and bonds to the intrusion device and the body
panel when exposed to the e-coat process as well as other paint
operation cycles encountered in a final vehicle assembly facility.
In addition, it is contemplated that the present invention may
utilize an application of expandable material directly to a
structural member or trim component of an automotive vehicle in an
automated or otherwise expedited manufacturing process which may
involve heating through traditional methods as well as welding and
radiation curable technology or cleaning the selected member or
part prior to application to assist in adhesion of the expandable
material.
[0008] In a particular non-limiting embodiment, a plurality of
pellets comprised of the vibration damping material or medium are
transformed from a solid or dry chemical state to a visco-elastic
stage through the use of a suitable mini-applicator which processes
the pellets at a temperature sufficient to transform the pellets
into a visco-elastic elastic material capable of flowing onto the
external surface of a intrusion device in a desired consistency,
thickness, and pattern.
[0009] The heat application and other shear functions from the
mini-applicator allows the material to flow in a uniform shape and
manner as it is extruded onto an external surface of the intrusion
device, such as a door intrusion beam, where it bonds. Once applied
to the external surface of the intrusion device by the
mini-applicator and no longer exposed to the heat source emanating
from the mini-applicator, the material returns to it solid or dry
chemical state and thereby remains disposed in place along the
selected portion of the intrusion device. The intrusion device is
then mounted within an automotive door assembly or other panel
assembly by the vehicle manufacture in accordance with
manufacturing techniques that are well known in the art. As the
assembly is prepared for final assembly of the vehicle, it is
processed through e-coat or other heat-inducing paint operations
which result in expansion and bonding of the material from the
intrusion device to either or both of the outer panel or the inner
panel of the selected automotive closure panel, such as a door
frame assembly having an inner door panel and an outer door panel,
where it cures and remains in place. It is contemplated that the
material expands from the external surface of the intrusion device
and cross-links to the substrates, which can comprise either of
both of a door inner panel and the door outer panel, thereby
serving to reduce the noise and vibration emanating from the door
assembly. Although the preferred embodiment discloses the material
essentially chemically cross-linking from the external surface of
an intrusion device, such as a door intrusion beam, into contact
with the door outer panel, it will be appreciated that various
patterns and applications of the material along the intrusion
device would allow the material to expand and chemically cross-link
with either or both of the door inner panel and door outer panel as
well as any other substrate that may be utilized or encountered in
a door assembly or other application which would facilitate either
passenger of cargo access to a vehicle.
[0010] In one embodiment the vibration reducing medium is
extruded-in-place onto an intrusion device in a continuous or
non-continuous extrusion adjacent to one or more inner walls
defining a cavity within an automotive door assembly. The vibration
reducing medium is activated to accomplish transformation (e.g.,
expansion or flow) of the active polymer or polymer within the
cavity after the door assembly is mounted onto the vehicle and the
vehicle is exposed to heat as it is processed through the e-coat
coat and paint operation cycles of a final automotive assembly
plant, which is well known in the art. The resulting structure
includes a wall or expansive extrusion that is coated over at least
a portion of its surface with the vibration reducing medium acting
to reduce vibration during transport and during functional
operation of the door assembly. It will be appreciated that a
preferred vibration reduction medium would consist of a damping
material comprising a number of chemical formulations including,
but not limited to, metal (such as steel, aluminum, etc.), rubber
(such as a butyl or isobutylene polymer, copolymer, or similar
elastomer having good damping characteristics), and plastic polymer
chemistry (ideally material that would remain rigid at temperatures
generally encountered by an automotive body skin during operation
of the vehicle, for example -40.degree. C. to 190.degree. C.
DESCRIPTION OF THE DRAWINGS
[0011] The features and inventive aspects of the present invention
will become more apparent upon reading the following detailed
description, claims, and drawings, of which the following is a
brief description:
[0012] FIG. 1 is a cutaway plan view of a vehicle door assembly
with a vibration reducing material extruded-in-place with
continuous extrusion in accordance with the present invention prior
to activation of the material.
[0013] FIG. 2 is a cutaway plan view of a vehicle door assembly
with a vibration reducing material extruded-in-place with
non-continuous extrusion in accordance with the present invention
prior to activation of the material.
[0014] FIG. 3 is a cutaway plan view of a vehicle door assembly
utilizing the vibration reducing material of the present invention
applied to selected portions of the door frame assembly, including
the belt-line reinforcement member.
DESCRIPTION OF PREFERRED EMBODIMENT
[0015] FIG. 1 illustrates an example of an automotive door frame
assembly 10 typically encountered in the manufacture of automotive
vehicles which includes a door intrusion device 12. As will be
appreciated, it is common for such structures to include a
plurality of hollow-portioned panel members that are joined and
shaped to define the door inner panel 14, within which there are
cavities. As will be recognized, examples of a suitable door frame
assembly 10 may include cargo doors, lift gates, hatchbacks,
sliding doors, easy access third doors, door handles, locks, window
assemblies or other vehicle doors and door components, sub-frame
construction, or the like. One such structure in FIG. 1, for
purposes of illustration (without limitation) includes a door
intrusion device 12 which may be in the form of a door intrusion
beam. Although the present invention may be used in other portions
of a door frame assembly 10 that do not require the presence of a
door intrusion device 12 as well as other automotive closure panel
assemblies other than doors, the intrusion device 12 is typically
comprised of metal (e.g., steel, aluminum, magnesium based, or the
like) and may be cold stamped, hot stamped, roll-formed, a tubular
beam, a hollow tubular beam, or a hydroformed section. It is also
contemplated that the intrusion device 12 could be formed of
composite or other high strength polymeric materials depending upon
the structural reinforcement required for specific applications of
the present invention.
[0016] As stated, it is contemplated that a variety of automotive
closure panel applications may be treated in accordance with the
present invention. In FIG. 1 there is shown a portion of the frame
assembly 10 that comprises an intrusion device 12 which bridges the
assembly 10 at a first end 16 and a second end 17, the frame 10
assembly thereby defining the door panel compartment. As
illustrated in the cutaway view of FIG. 1, the door intrusion
device 12 is generally tubular and assists in the reinforcement of
the assembly 10 with suitable cross sectional configuration or
reinforcements depending upon the size or configuration of the
particular application. The intrusion device 12 itself might be
hollow and further reinforced, using technology such as that
disclosed in U.S. Pat. Nos. 4,922,596, 4,978,562, 5,124,186, and
5,884,960 and commonly owned, co-pending U.S. application Ser. Nos.
09/502,686 filed Feb. 11, 2000 and Ser. No. 09/524,961 filed Mar.
14, 2000, all of which are expressly incorporated by reference.
[0017] Vibration reduction of the assembly and door intrusion
device 12 is accomplished according to the present invention by an
extrusion-in-place or mini-extrusion application of an appropriate
pattern 18 of a vibration reduction material 20 of the type
discussed herein disposed along either or both of the intrusion
device 12 or other selected portion of the door frame assembly 10
such as the belt-line reinforcement member 22 which is formed
between the assembly and a corresponding window structure or other
portion of the assembly 10 suitable for application of the material
20. The material 20 is applied over at least a portion of the
intrusion device 12 or belt-line 22 in accordance with the
extrusion techniques, apparatus, and methods set forth in commonly
assigned U.S. Pat. No. 5,358,397, incorporated by reference. It
will also be appreciated that the material 20 may comprise pellets
extruded along the intrusion device 12 and/or the belt-line 22 in a
variety of continuous and non-continuous patterns. In this regard,
it is contemplated that technology disclosed in co-pending U.S.
application Ser. No. 09/631,21 for a Sound Absorption System For
Automotive Vehicles, incorporated by reference, may be employed in
the present invention. FIG. 1 illustrates an example of this by
showing a continuously extruded pattern 18 of the material 20
uniformly extruded along the intrusion device 12. The vibration
reduction material 20 preferably is fixedly secured to at least one
portion of the intrusion device 12 by one of its own external
surfaces. Accordingly, it is preferred that the vibration reduction
material 20 is a polymeric foam that includes a bonding component,
which maintains it in place on the external surface of the
intrusion device 12, and thereafter, upon heat activation maintains
its adhesion to the intrusion device 12 but expands to form a foam
within the hollow cavity between the door inner panel and the outer
panel of the selected frame assembly 10. Thus, preferably the
vibration reduction material 20 is a heat-activated material having
an adhesive component.
[0018] Though other heat-activated materials are possible, a
preferred heat activated material is an expandable or flowable
polymeric formulation, and preferably one that is activate to foam,
flow or otherwise change states when exposed to the heating
operation of a typical automotive final assembly painting
operation. A particularly preferred material is an active polymer
formulated in pellet form with each pellet typically 1-20 mm in
diameter and generally, but not necessarily, spherical in shape to
facilitate the flow of such pellets through the mini-applicator
more fully disclosed in commonly-owned U.S. Pat. No. 5,358,397
("Apparatus For Extruding Flowable Materials"), incorporated by
reference and other olefinic polymer-based acoustic foams, and more
particularly an ethylene based polymer. For example, without
limitation, in one embodiment, the polymeric foam is based on
ethylene copolymer or terpolymer that may possess an alpha-olefin.
As a copolymer or terpolymer, the polymer is composed of two or
three different monomers, i.e., small molecules with high chemical
reactivity that are capable of linking up with similar molecules.
Examples of particularly preferred polymers include ethylene vinyl
acetate, EPDM, or a mixture thereof. Without limitation, other
examples of preferred foam formulation that are commercially
available include polymer-based material commercially available
from L&L Products, Inc. of Romeo, Mich., under the designations
as L-2105, L-2100, L-7005 or L-2018, L-7101, L-7102, L-2411,
L-2412, L-4141, etc. and may comprise either open or closed cell
polymeric base material
[0019] A number of other suitable materials are known in the art
and may also be used for vibration reduction. One such foam
preferably includes a polymeric base material, such as an
ethylene-based polymer which, when compounded with appropriate
ingredients (typically a blowing and curing agent), expands and
cures in a reliable and predicable manner upon the application of
heat or the occurrence of a particular ambient condition. From a
chemical standpoint for a thermally activated material, the
vibration reducing foam is usually initially processed as a
flowable thermoplastic material before curing. It will cross-link
upon curing, which makes the material resistant of further flow or
change of final shape.
[0020] One advantage of the preferred vibration reduction material
20 is that the preferred material can be processed in several ways,
thereby affording substantial design and production flexibility.
For instance, without limitation, the preferred materials can be
processed by extrusion techniques discussed herein, injection
molding, compression molding, or with a mini-applicator discussed
herein. This enables the formation and creation of vibration
reduction shaping that exceed the capability and
maintenance/cleanliness issues of most prior art materials, which
comprise "wet" chemistry compositions. In one preferred embodiment,
the material 20 or pellet or even a plurality of pellets (in its
uncured state) is generally dry or relatively free of tack to the
touch. In another embodiment, the material 20 is applied to the
intrusion device 12 through a robotic extrusion process, which
serves to minimize the maintenance of wet or tacky mediums and
further functions to reduce labor demand on the vehicle
manufacturer.
[0021] In a particular non-limiting embodiment, the material 20 is
applied to the intrusion device 12 through the use of a
mini-applicator which applies heat and shear to the material 20 in
accordance with the teachings of commonly-owned U.S. Pat. No.
5,358,397 ("Apparatus For Extruding Flowable Materials"), which, in
turn, transforms the material 20 consisting of a plurality of
pellets from a solid or dry chemical state to a visco-elastic state
inside the mini-applicator for application of the material 20 to
the desired surface in a desired pattern or consistency, namely an
external surface of an intrusion device 12 generally found in
automotive vehicles, such as a door intrusion beam.
[0022] It is contemplated that the mini-applicator prepares the
material 20 into a visco-elastic state which can easily and
uniformly be applied to an exterior surface of the intrusion device
12 in a relatively clean manner where it hardens and bonds. It will
be appreciated that the material 20 can be applied to the intrusion
device 12 in a uniform shape, thickness, or consistency which could
comprise a continuous flow, a non-continuous flow, a pattern
application, and even a ribbed design depending upon the particular
application and sizing found between the related intrusion device
12 and the inner and outer panels of the chosen automotive panel
assembly. Once the mini-applicator applies the material 20 to the
intrusion device 12 in the desired shape and pattern, the material
20 cools at the ambient temperature found in the manufacturing
facility which allows the material 20 to return to its original
solid or dry chemical state thereby bonding and adhering the
material 20 to the external surface of the intrusion device 12. The
intrusion device 12 is then place mounted onto-the door assembly 10
prior to assembly of the vehicle by the vehicle manufacturer. The
door assembly 10 is then integrated into the vehicle for
application of the e-coat process as well as other paint operation
cycles commonly found in an automotive manufacturing facility.
These and paint operating cycles generally involve exposure to heat
through cure ovens which activate the material 20 and allow it to
expand, thereby chemically cross-linking the material 20 on the
external surface of the intrusion device 12 to either or both of
the inner door panel or the outer door panel thereby providing a
walled or expansive structure which serves to reduce vibration and
noise during transport of the vehicle and operation of the
door.
[0023] While the preferred materials for fabricating the vibration
reduction material have been disclosed, the material 20 can be
formed of other materials (e.g., foams regarded in the art as
structural foams) provided that the material selected is
heat-activated or otherwise activated by an ambient condition (e.g.
moisture, pressure, time or the like) and cures in a predictable
and reliable manner under appropriate conditions for the selected
application. One such material is the polymeric based resin
disclosed in commonly owned, co-pending U.S. patent application
Ser. No. 09/268.810 (fled Mar. 8, 1999), the teachings of which are
incorporated herein by reference.
[0024] Some other possible materials include, but are not limited
to, polyolefin materials, copolymers and terpolymers with at least
one monomer type an alpha-olefin, phenol/formaldehyde materials,
phenoxy materials, and polyurethane. See also, U.S. Pat. Nos.
5,266,133; 5,766,719; 5,755,486; 5,575,526; 5,932,680; and WO
00/27920 (PCT/US 99/24795) (all of which are expressly incorporated
by reference). Examples of suitable melt flow materials include,
without limitation, formulations found in a commonly owned
co-pending application for a Paintable Seal System filed Aug. 7,
2000, hereby incorporated by reference. In general, the desired
characteristics of the resulting material include relatively low
glass transition point, and good corrosion resistance properties.
In this manner, the material does not generally interfere with the
materials systems employed by automobile manufacturers. Moreover,
it will withstand the processing conditions typically encountered
in the manufacture of a vehicle, such as the e-coat priming,
cleaning and degreasing and other coating processes, as well as the
painting operations encountered in final vehicle assembly.
[0025] In this regard, in applications where a heat activated,
thermally expanding material is employed as the vibration reduction
material, a consideration involved with the selection and
formulation of the material is the temperature at which a material
reaction or expansion, and possibly curing, will take place. For
instance, in most applications, it is undesirable for the material
20 to be reactive at room temperature or otherwise at the ambient
temperature in a production line environment since, in one
embodiment, the material 20 is extruded onto the intrusion device
by a supplier and then shipped to the vehicle manufacturer as an
integrated product. More typically, the material 20 becomes
reactive at higher processing temperatures, such as those
encountered in an automobile assembly plant, when the material 20
is processed along with the vehicle components at elevated
temperatures or at higher applied energy levels, e.g., during
e-coat preparation steps and other paint cycles. While temperatures
encountered in an automobile e-coat operation may be in the range
of about 145.degree. C. to about 210.degree. C. (about 300.degree.
F. to 400.degree. F.), primer, filler and paint shop applications
are commonly about 93.33.degree. C. (about 200.degree. F.) or
higher. The material is thus operative throughout these ranges. If
needed, blowing agent activators can be incorporated into the
composition to cause expansion at different temperatures outside
the above ranges.
[0026] Generally, suitable vibration reduction materials have a
range of expansion ranging from approximately 0 to over 1000
percent. The level of expansion of the vibration reduction material
20 may be increased to as high as 1500 percent or more. The
material may be expandable to a degree (or otherwise situated on a
surface) so that individual nodes remain separated from one another
upon expansion, or they may contact one another (either leaving
interstitial spaces or not).
[0027] In another embodiment, the vibration reduction material is
provided in an encapsulated or partially encapsulated form, which
may comprise a pellet, which includes an expandable foamable
material, encapsulated or partially encapsulated in an adhesive
shell. An example of one such system is disclosed in commonly
owned, co-pending U.S. application Ser. No. 09/524,298 ("Expandable
Pre-Formed Plug"), hereby incorporated by reference.
[0028] Moreover, the vibration reduction material may include a
melt-flowable material such as that disclosed in U.S. Pat. No.
6,030,701 (expressly incorporated by reference).
[0029] Referring again to FIG. 1, there is shown one example of a
pattern 18 for the vibration reduction material 20 applied to an
external surface of an intrusion device 12 prior to heat activation
or foaming wherein the material 20 is continuously extruded. FIG. 2
illustrates a non-continuous pattern 18 of the material 20 achieved
by non-continuous extrusion. FIG. 3 illustrates the placement of
the vibration reduction material along selected portions of the
door frame assembly 10 which can include the belt line
reinforcement 22 or other visible or exterior portions of an
automotive vehicle. The skilled artisan will appreciate that the
displacement pattern of the material 20 shown in FIGS. 1-3 are
non-limiting examples of many patterns that may be employed. It is
contemplated that the material, after expansion, may contain a
plurality of nodes which are generally disposed in a random pattern
and are generally suitable for the absorption of vibrations and
other sound frequencies emanating from the door assembly or
otherwise generated by the vehicle or its components including road
induced noise and absorb the same. In one preferred embodiment,
such patterns and the selection of the material is made for
achieving generally miniaturized chamber areas, where it is
believed that vibrational energy can be dissipated through the
vibrational reduction material.
[0030] In addition, as discussed previously, preformed patterns may
also be employed such as those made by extruding a sheet (having a
flat or contoured surface) and then die cutting it according to a
predetermined configuration in accordance with the intrusion
device, and applying it thereto, wherein the extrusion may be
either continuous, as shown in FIG. 1, or non-continuous, as shown
in FIG. 2.
[0031] The skilled artisan will appreciate that the use of the
vibration reduction system disclosed herein is not intended as
being limited only to illustrate the door assembly locations shown
in FIG. 1. The present invention can be used in any location within
a door or hatch entry into an automotive vehicle that may or may
not utilize an intrusion device 12. For instance, other reinforced
locations are also possible including, but not limited to, sliding
side doors, hatchbacks, rear cargo doors, gates, and crew/club cab
designs and the like with or without the presence of an intrusion
device 12.
[0032] Moreover, the skilled artisan will appreciate that the
vibration reduction system may be employed in combination with or
as a component of a conventional sound blocking baffle, or a
vehicle structural reinforcement system, such as is disclosed in
commonly owned co-pending U.S. application Ser. Nos. 09/524,961 or
09/502,686 (hereby incorporated by reference).
[0033] A number of advantages are realized in accordance with the
present invention, including, but not limited to, the ability to
manufacture an integrated intrusion device structure ready for
delivery and assembly at a vehicle assembly plant without the need
for application of pumpable products, wet chemical products, and
multiple sets of tools, such as for other prior art.
[0034] The preferred embodiment of the present invention has been
disclosed. A person of ordinary skill in the art would realize
however, that certain modifications would come within the teachings
of this invention. Therefore, the following claims should be
studied to determine the true scope and content of the
invention.
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