U.S. patent application number 10/262493 was filed with the patent office on 2004-04-22 for structural reinforcement assembly and a method for structurally reinforcing a member or a portion of an article of manufacture.
Invention is credited to Wycech, Joseph.
Application Number | 20040074150 10/262493 |
Document ID | / |
Family ID | 32068252 |
Filed Date | 2004-04-22 |
United States Patent
Application |
20040074150 |
Kind Code |
A1 |
Wycech, Joseph |
April 22, 2004 |
Structural reinforcement assembly and a method for structurally
reinforcing a member or a portion of an article of manufacture
Abstract
An assembly 12 and a method which utilizes the assembly 12 to
selectively and structurally strengthen and rigidize and/or stiffen
a member 10 which is operatively disposed within an article of
manufacture, such as an without limitation, a vehicle.
Particularly, the assembly 12 includes a selectively expandable
portion 18 which is inserted into the member 10 and selectively
expanded once it is inserted into the member 10.
Inventors: |
Wycech, Joseph; (Warren,
MI) |
Correspondence
Address: |
JOHN G. CHUPA
LAW OFFICE OF JOHN CHUPA & ASSOCIATES, P.C.
28535 ORCHARD LAKE ROAD
SUITE 50
FARMINGTON HILLS
MI
48334
US
|
Family ID: |
32068252 |
Appl. No.: |
10/262493 |
Filed: |
October 1, 2002 |
Current U.S.
Class: |
52/2.13 ;
52/2.11 |
Current CPC
Class: |
B62D 29/002
20130101 |
Class at
Publication: |
052/002.13 ;
052/002.11 |
International
Class: |
E04B 001/34; E04G
011/04 |
Claims
What is claimed is:
1. A structural reinforcement assembly for supporting a member
having a cavity of a certain volume, said assembly comprising: a
first selectively expanded portion; and a second portion which is
attached to said first selectively expanded portion and which
selectively communicates a gas into said first portion, effective
to selectively expand said first portion, thereby occupying at
least a portion of said certain volume.
2. The structural reinforcement assembly of claim 1 wherein said
first selectively expanded portion is formed from an elastomeric
material.
3. The structural reinforcement assembly of claim 1 wherein said
member has a pair of opposing surfaces which define said cavity,
said selective expansion of said first portion causing said first
portion to abut each of said pair of opposing surfaces.
4. The structural reinforcement assembly of claim 3 wherein said
gas comprises air.
5. The structural reinforcement assembly of claim 3 wherein said
gas comprises carbon dioxide.
6. The structural reinforcement assembly of claim 3 wherein said
second portion comprises a nozzle.
7. A structural reinforcement assembly comprising: a selectively
expandable balloon assembly; and a second portion which is
selectively and removably coupled to said balloon assembly and
which is effective to selectively expand said balloon.
8. The structural reinforcement assembly of claim 7 wherein said
balloon assembly comprises: a balloon; and a nozzle.
9. The structural reinforcement assembly of claim 8 wherein said
nozzle is integrally formed with said balloon.
10. The structural reinforcement assembly of claim 9 wherein said
second portion comprises a source of gas which is selectively
coupled to said balloon assembly to inject an amount of gas into
said balloon.
11. The structural reinforcement assembly of claim 10 wherein said
gas comprises air.
12. The structural reinforcement assembly of claim 10 wherein said
gas comprises carbon dioxide.
13. The structural reinforcement assembly of claim 10 wherein said
balloon is formed from an elastomeric material.
14. The structural reinforcement assembly of claim 9 wherein said
second portion comprises a source of foam which is selectively
coupled to said balloon assembly to inject an amount of foam into
said balloon.
15. The structural reinforcement assembly of claim 14 wherein said
foam further comprises acoustic foam.
16. The structural reinforcement assembly of claim 14 wherein said
foam further comprises structural foam.
17. The structural reinforcement assembly of claim 10 further
including a source of foam, said source of foam being effective to
selectively deposit said foam around said balloon.
18. The structural reinforcement assembly of claim 17 wherein said
source of foam comprises a source of structural foam.
19. The structural reinforcement assembly of claim 17 wherein said
source of foam comprises a source of acoustic foam.
20. The structural reinforcement assembly of claim 13 wherein said
elastomeric material comprises rubber.
21. The structural reinforcement assembly of claim 13 wherein said
balloon is I-shaped.
22. The structural reinforcement assembly of claim 13 wherein said
balloon is U-shaped.
23. The structural reinforcement assembly of claim 13 wherein said
balloon is M-shaped.
24. A method for structurally reinforcing a member comprising the
steps of: placing at least one selectively expandable portion into
said member; and expanding said at least one selectively expandable
portion in a controlled manner.
25. The method of claim 24 wherein said method further comprises
the steps of: acquiring a certain material; and placing said
certain material into said member, thereby allowing said certain
material to cooperate with said at least one selectively expandable
portion to reinforce said member.
26. The method of claim 25 wherein said certain material comprises
foam.
27. The method of claim 25 wherein said certain material comprises
Terocore.TM..
28. The method of claim 25 wherein said certain material comprises
Betocore.TM..
29. The method of claim 24 wherein said step of expanding said at
least one selectively expandable portion comprises the steps of:
acquiring a source of gas; coupling said source of gas to said at
least one selectively expandable member; and communicating an
amount of gas into said at least one selectively expandable
portion.
30. The method of claim 29 wherein said gas comprises air.
31. The method of claim 29 wherein said gas comprises carbon
dioxide.
32. The method of claim 25 wherein said expandable member is
I-shaped.
33. The method of claim 25 wherein said expandable member is
U-shaped.
34. The method of claim 25 wherein said expandable member is
M-shaped.
35. The method of claim 25 further comprising the steps of:
providing a second selectively expandable portion; placing said
second selectively expandable portion within said member at a
certain distance from said at least one selectively expandable
portion; and communicating said gas, from said source of gas, to
said second selectively expandable member, wherein said second
selectively expandable portion cooperates with said at least one
selectively expandable portion to contain said certain material.
Description
FIELD OF THE INVENTION
[0001] The present invention generally relates to a structural
reinforcement assembly and to a method for structurally reinforcing
a member or a portion of an article of manufacture and more
particularly, to an assembly which may be selectively inserted into
a space and which may be selectively expanded in a manner which is
effective to fill such space, and to a method which utilizes such
an assembly.
BACKGROUND OF THE INVENTION
[0002] An assembly, such as but not limited to an automobile,
includes several members which form the structure of the assembly.
One non-limiting example of such a structural member includes but
is not limited to a pillar of an automobile.
[0003] In order to reduce cost, these structural members are
typically hollow and contain one or more reinforcement beams, such
as an "I" beam. While these reinforcement beams do provide support
and rigidity to these structural members, such support and rigidity
is often lost or undesirably impaired when a repair is made to the
assembly. That is, oftentimes such a repair (e.g., a repair to the
body of the automobile after a collision) necessitates the removal
of one or more of these structural members, thereby undesirably
reducing the rigidity, stiffness, and overall structural integrity
of the structural members of the assembly. Such a reduction in
overall rigidity, stiffness, and integrity reduces the protection
provided by the assembly and increases the amount of damage done to
the assembly in the event of another collision.
[0004] There is therefore a need for an apparatus and a method to
selectively provided increased rigidity, stiffness, and integrity
to a structural member, such as and without limitation, a
structural member which is found within an automobile.
SUMMARY OF THE INVENTION
[0005] It is a first non-limiting advantage of the invention to
provide a method and an apparatus for selectively rigidizing a
structural support member.
[0006] It is a second non-limiting advantage of the present
invention to provide a method and an apparatus for selectively
rigidizing a structural support member in a cost effective and
relatively simple manner.
[0007] It is a first non-limiting feature of the present invention
to provide a structural reinforcement assembly for supporting a
member having a cavity of a certain volume. Particularly, the
assembly comprises: a first selectively expanded portion; and a
second portion which is attached to the first selectively expanded
portion and which selectively communicates a gas into the first
portion, effective to selectively expand the first portion, thereby
occupying at least a portion of the certain volume.
[0008] It is a second non-limiting feature of the present invention
to provide a structural reinforcement assembly. Particularly, the
assembly comprises a selectively expandable balloon assembly; and a
second portion which is selectively and removably coupled to the
balloon assembly and which is effective to selectively expand said
balloon.
[0009] It is a third non-limiting feature of the present invention
to provide a method for structurally reinforcing a member.
Particularly, the method comprises the steps of: placing at least
one selectively expandable portion into the member; and expanding
the at least one selectively expandable portion in a controlled
manner.
[0010] These and other features and advantages of the present
invention will become apparent from a reading of the detailed
description of the preferred embodiment of the invention and by
reference to the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a partial perspective view of a structural support
member receiving a structural support assembly which is made in
accordance with, the teachings of the preferred embodiment of the
invention;
[0012] FIG. 2 is a partial perspective view of a structural support
member having received the structural support assembly which is
shown in FIG. 1;
[0013] FIG. 3 is partial side view of the structural support member
which is shown in FIGS. 1 and 2 and further showing the selective
inflation of the received support assembly which is made in
accordance with the teachings of the preferred embodiment of the
invention;
[0014] FIG. 4 is a view which is similar to that which is shown in
FIG. 3 but which shows a complete inflation of the support assembly
which is made in accordance with the teachings of the preferred
embodiment of the invention;
[0015] FIG. 5 is a view which is similar to that which is shown in
FIG. 4 but which shows the selective removal of the source of gas
which is used to selectively inflate the support assembly which is
made in accordance with the teachings of the preferred embodiment
of the invention;
[0016] FIG. 6 is a perspective view of the support assembly which
is shown in FIG. 5;
[0017] FIG. 7 is a partial perspective view of a support member
having the support assembly which is made in accordance with the
teachings of the preferred embodiment of the invention but deployed
within the support member in an alternate manner;
[0018] FIG. 8 is a partial perspective view of a support member
having a support assembly which is made in accordance with the
teachings of an alternate embodiment of the invention;
[0019] FIG. 9 is a perspective view of a support member having a
support assembly which is made in accordance with the teachings of
yet another alternate embodiment of the invention;
[0020] FIG. 10 is a perspective view of a support member having a
support assembly which is made in accordance,with the teachings of
yet another alternate embodiment of the invention;
[0021] FIG. 11 is a perspective view of a support member having a
support assembly which is made in accordance with the teachings of
yet another alternate embodiment of the invention; and
[0022] FIG. 12 is a perspective view of a support member having a
support assembly which is made in accordance with the teachings of
yet another alternate embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT OF THE
INVENTION
[0023] Referring now to FIGS. 1-5 there is shown a structural
support member 10 in combination with a structural support assembly
12 which is made in accordance with the teachings of the preferred
embodiment of the invention.
[0024] Particularly, the structural support member 10 has a cavity
14 which may be formed due to the removal of all or part of a
support beam or member, such as and without limitation, an "I"
beam. As is further shown, the assembly 12 includes a selectively
inflatable balloon member 16 having a selectively inflatable
portion 18 and a nozzle 20 which is communicatively coupled to
and/or which may be integrally formed with the selectively
inflatable portion 18. Particularly, the selectively inflatable
portion 18 includes or forms a cavity 24 which communicates with
the opening 30 formed within the nozzle 20. In one non-limiting
embodiment of the invention, the assembly 12 includes an air pump
34, although in another non-limiting embodiment, the assembly 12
only comprises the inflatable balloon member or assembly 16.
Further, in one non-limiting embodiment of the invention, the
selectively inflatable portion 18 is formed from rubber or some
other commercially available elastomeric material and the
selectively inflatable portion has a uniform thickness and a
substantially uniform elasticity along each point on its
surface.
[0025] In the first step in the method of utilizing the assembly
12, as shown best in FIG. 1, a hole or opening 40 is formed within
the member 10, effective to allow communication with the cavity 14.
In the second step of the methodology of the preferred embodiment
of the invention, the selectively inflatable portion 18 is inserted
into the cavity 14 through the formed hole or opening 40 such that
the nozzle 20 is made to protrude from the formed hole or opening
40 into the ambient environment 50 in which the structural support
member 10 resides.
[0026] In the third step of the methodology of the preferred
embodiment of the invention, as best shown in FIG. 3, the air pump
34 is operatively coupled to the protruding nozzle 20. Air is then
communicated into the cavity 24, through the opening 30, by the air
pump 34, effective to begin to cause the selectively inflatable
portion 18 to inflate within the cavity 14. In the preferred
embodiment of the invention, the selectively inflatable portion 18
uniformly inflates within the cavity 14. That is, the term
"uniformly inflates" means that each point on the surface of the
selectively inflatable portion 18 moves or attempt to move in
substantially the same distance within the cavity 14.
[0027] In other non-limiting embodiments of the invention, portion
18 may be inflated or filled in a non-uniform manner (e.g., a first
section of portion 18 is inflated more fully than a second portion
18).
[0028] In the fourth step of the methodology of the preferred
embodiment of the invention, as shown best in FIG. 4, the
selectively inflatable portion 18 is either fully inflated or is
inflated by a desired amount within the cavity 14. In the most
preferred embodiment of the invention, the selectively inflatable
portion 18 is inflated to the fullest possible amount without
breaking the portion 18. Importantly, due to the substantially
uniform nature of the inflation of the selectively inflatable
portion 18, upon completion of this fourth step, the selectively
inflated portion 18 positively contacts at least two opposed
interior walls, such as walls 60, 62, thereby rigidizing the
structural support member 10 in a direction passing through each of
the walls 60, 62. If it is desired to rigidize the structural
support member 10 along a different direction, different opposed
interior walls might need to be contacted by the selectively
inflatable portion 18, thereby requiring a placement of the portion
18 to be different from that which is shown in FIGS. 1-6. That is,
the portion 18 might need to actually touch the bottom of the
member 10 which is not shown in the FIGS. 1-5 since the member 10
has been sectionalized in the bottom portion or area.
[0029] The fifth step of the methodology of the preferred
embodiment of the invention, as best shown in FIG. 5, requires the
removal of the air pump 34 from the portion 20, thereby leaving the
selectively inflatable portion operatively and inflatably disposed
within the cavity 14 in a manner which is effective to rigidize and
structurally strengthen the member 10. It should be appreciated
that the air pump 34 may be selectively replaced by a source of
carbon dioxide or another gas which may be selectively communicated
into the cavity 24 and that the selectively inflatable portion 18
may be adapted to achieve substantially any desired shape and size.
In one non-limiting embodiment, the air pump 34 may be replaced by
an industrial foam pump. That is, in this non-limiting embodiment,
an industrial foam, acoustical foam, or structural foam, such as
Terocore.TM. or Betocore.TM. may be selectively injected within the
inflatable portion 18, thereby utilizing the inflatable portion 18
to operatively contain the foam while concomitantly preventing the
foam from expanding, traversing, or running into unwanted or
undesirable areas.
[0030] In an alternate embodiment of the invention, as shown best
in FIG. 7, foam 80 is placed within the cavity 14 after the
selectively inflatable portion 18 is inserted into the cavity 14
and selectively inflated, thereby cavitating or occupying a portion
of the cavity 14 (e.g., approximately one-third to about one-half
of the volume of cavity 14 is occupied by the inflatable portion
18). It should be appreciated that, in this manner, the foam 80 is
injected into cavity 14 and the foam 80 surrounds the inflated
portion 18. That is, inflated portion 18 acts to define an area in
which foam 80 is displaced or prevented from occupying within the
cavity 14, thereby reducing the amount of foam 80 which is needed
to "fill" cavity 14.
[0031] In yet another alternate embodiment of the invention, as
shown best in FIG. 8, two or more substantially identical portions
18 (denoted as 18' and 18" in FIG. 8) are selectively inserted and
inflated within the cavity 14 and foam material 90 is inserted,
after the portions 18' and 18" are inserted into and selectively
inflated within the cavity 14. It should be appreciated that the
material 90 and 80 may alternatively comprise foam based material
or some other commercially available material.
[0032] Furthermore, in this alternate embodiment of the invention,
also as best shown in FIG. 8, one portion 18' is operatively
disposed within a desired area of cavity 14 and either inflated
with air or another gas, as discussed above. Furthermore, a second
and substantially identical portion 18" is disposed within the same
cavity 14 at a predetermined distance apart from portion 18' (i.e.,
allowing a predetermined space of cavity 14 between the two
portions 18' and 18") and filled with air or gas in the same manner
as discussed above in reference to portion 18'. Moreover, the foam
90 is inserted within the predetermined space of cavity 14 created
by the portions 18' and 18". In this manner, the portions 18' and
18" cooperatively act as barriers to contain the foam 90. It should
be appreciated that, in this manner, the portions 18' and 18"
locate and contain the foam during cure, thereby concomitantly
reducing the amount of required material or foam 90.
[0033] It should be understood that the cavity 14 is not limited to
the geometrical configuration (i.e., generally rectangular) which
is shown in FIGS. 1-5 and 7-8. Rather, as should be appreciated,
the geometrical configuration of cavity 14 may be substantially any
geometrical configuration. For example and without limitation and,
as shown in FIG. 9, the applications of the present invention are
equally applicable to a substantially round or tubular member, such
as member 114. In one non-limiting embodiment, member 114 is a
portion of a conventional vehicular driveshaft or a conventional
vehicular steering column. It should be appreciated that other
geometrical configurations or other tubular members or portions may
also be supported using the abovementioned embodiments of the
invention, and nothing in this description is meant to limit the
shape, size, and geometrical configuration of cavities 14, 114 to
that which is illustrated within FIGS. 1-5 and 7-9.
[0034] Referring now to FIG. 10, there is shown a structurally
supported member 200 which is made in accordance with the teachings
of an alternate embodiment of the invention. As shown, member 200
includes a generally hollow and rectangular member 114 into which a
selectively inflatable portion 218 is inserted (i.e., in the manner
which is described in reference to FIGS. 1-5). It should be
appreciated that, in this alternate embodiment, the selectively
inflatable portion 218 is geometrically configured to be generally
"I" or "H" shaped. That is, inflatable portion 218 includes a first
portion 202 and a second portion 204 which is parallel to the first
portion (e.g., the top and bottom portions of the letter "I").
Moreover, inflatable portion 218 includes a third portion 206 which
separates the first and second portions 202, 204 and which is
perpendicular to and intersects the first and second portions 202,
204 (e.g., the middle portion of the letter "I"). In this alternate
embodiment, the selectively inflatable portion 218 may either be
filled or selectively inflated with air, another type of gas, or
foam. In this manner the selectively inflatable portion 218 may
also act as a containment bladder for a foam, thereby providing
member 200 with structural support and/or acoustical dampening
while concomitantly containing and conserving the amount of
material (e.g., foam) which would otherwise be required to fill the
entire hollow area of member 200. It should be understood that
nothing in this description is meant to limit the geometrical
configuration of the member 200 to that which is shown within FIG.
10. Rather, as discussed above, substantially any desired
geometrical configuration may be structurally supported by the
selectively inflatable member 218.
[0035] Referring now to FIG. 11 there is shown a structurally
supported member 300 which is made in accordance with the teachings
of yet another alternate embodiment of the invention. As shown,
member 300 is substantially identical to the member 200 of FIG. 10.
However, as shown in FIG. 11, the selectively inflatable portion
318 is geometrically configured to be shaped substantially similar
to the letter "C" or "U" (i.e., the portion 318 includes two
substantially identical and parallel members (the top and bottom
portions of the letter "C"), as well as a perpendicular portion
which separates the top and bottom parallel portions (the left and
middle portion of the letter "C"). In this alternate embodiment,
the selectively inflatable portion 318 may either be filled or
selectively inflated with air, another type of gas, or foam. In
this manner, the selectively inflatable portion 318 may also act as
a containment bladder for foam, thereby providing member 300 with
structural support and/or acoustical dampening while concomitantly
containing and conserving the amount of material (e.g., foam) which
would otherwise be required to fill the entire hollow area of
member 300. It should be understood that nothing in this
description is meant to limit the geometrical configuration of the
member 300 to that which is shown within FIG. 11. Rather, as
discussed above, substantially any desired geometrical
configuration may be structurally supported by the selectively
inflatable member 318.
[0036] Referring now to FIG. 12, there is shown a structurally
supported member 400 which is made in accordance with the teachings
of yet another alternate embodiment of the invention. As shown,
member 400 is substantially identical to the members 200 and 300 of
FIGS. 10 and 11. However, as shown in FIG. 12, the selectively
inflatable portion 418 is geometrically configured to be shaped
substantially similar to the letter "W" or "M". In this alternate
embodiment, the selectively inflatable portion 418 may either be
filled or selectively inflated with air, another type of gas, or
foam. In this manner, the selectively inflatable portion 418 may
also act as a containment bladder for foam, thereby providing
member 400 with structural support and/or acoustical dampening
while concomitantly containing and conserving the amount of
material (e.g., foam) which would otherwise be required to fill the
entire hollow area of member 400. It should be understood that
nothing in this description is meant to limit the geometrical
configuration of the member 400 to that which is shown within FIG.
12. Rather, as discussed above, substantially any desired
geometrical configuration may be structurally supported by the
selectively inflatable member 418.
[0037] It should be understood that nothing in the above
description is meant to limit the geometrical configurations of the
selectively inflatable portions 18, 218, 318, and 418 to the shapes
which are described and shown in FIGS. 9-12. Rather, substantially
any desired geometrical configuration of an inflatable portion may
be substituted in the place of that which is shown in FIGS. 9-12.
Further, it should be understood that the geometrical
configurations of the selectively inflatable portions may be
designed or produced to administer a predetermined amount of
support and/or dampening characteristics. Moreover, it should be
appreciated that these shapes or geometrical configurations may be
used to provide support in discrete locations, while providing
clearances for fasteners, pins, tooling apertures or holes, and the
like. That is, a particular inflatable portion 18, 218, 318, or 418
may be utilized to ensure there is sufficient space for additional
members, structures, or portions to be placed through within a
cavity 14 containing the inflatable portion 18, 218, 318, or
418.
[0038] It is to be understood that the present invention is not
limited to the exact construction or method which has been
illustrated and described above, but that various modifications may
be made without departing from the spirit and the scope of the
inventions as are delineated in the following claims.
* * * * *