U.S. patent application number 11/020717 was filed with the patent office on 2005-08-04 for structurally reinforced panels.
This patent application is currently assigned to L&L Products, Inc.. Invention is credited to Barz, William J..
Application Number | 20050166532 11/020717 |
Document ID | / |
Family ID | 34810398 |
Filed Date | 2005-08-04 |
United States Patent
Application |
20050166532 |
Kind Code |
A1 |
Barz, William J. |
August 4, 2005 |
Structurally reinforced panels
Abstract
A structurally reinforced panel and a method of forming the
panel are disclosed. The reinforced panel includes a panel portion,
a reinforcement material and a backing material disposed
thereon.
Inventors: |
Barz, William J.; (St.
Clair, MI) |
Correspondence
Address: |
DOBRUSIN & THENNISCH PC
29 W LAWRENCE ST
SUITE 210
PONTIAC
MI
48342
US
|
Assignee: |
L&L Products, Inc.
Romeo
MI
|
Family ID: |
34810398 |
Appl. No.: |
11/020717 |
Filed: |
December 22, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60534755 |
Jan 7, 2004 |
|
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Current U.S.
Class: |
52/846 |
Current CPC
Class: |
B62D 29/002 20130101;
E04C 2/08 20130101; E04C 2/38 20130101; B62D 25/10 20130101; B60J
5/0452 20130101; B62D 27/026 20130101 |
Class at
Publication: |
052/731.7 |
International
Class: |
E04B 002/00 |
Claims
What is claimed is:
1. A structurally reinforced member for an automotive vehicle,
comprising: (a) a panel portion of the automotive vehicle; (b) a
reinforcement member having a length, the reinforcement member
being a laminate that includes: i) a reinforcement material layered
upon the panel portion; and ii) a backing material formed as layer
and having a rib, the backing material layered upon a surface of
the reinforcement material.
2. A structurally reinforced member as in claim 1 wherein the
reinforcement material is a two-component material that activates
to cure upon exposure of a first component to a second
component.
3. A structurally reinforced member as in claim 1 wherein the
reinforcement material is a heat activatable material that
activates to foam and cure upon exposure to a temperature
experienced in an e-coat or paint curing oven.
4. A structurally reinforced member as in claim 1 wherein the rib
is roll formed to have an arc.
5. A structurally reinforced member as in claim 1 wherein the
backing material is formed of metal.
6. A structurally reinforced member as in claim 5 wherein the
backing material is at least partially formed of aluminum or
steel.
7. A structurally reinforced member as in claim 1 wherein the panel
portion is part of a automotive vehicle panel selected from a
quarter panel, a side panel, a hood panel, a trunk panel or a door
panel.
8. A structurally reinforced member as in claim 1 wherein the
length is between about 30 cm and about 100 cm.
9. A structurally reinforced member as in claim 1 wherein the layer
of reinforcement material has a thickness between about 3 mm and
about 10 mm.
10. A structurally reinforced member as in claim 1 wherein the
reinforcement material is activatable to foam and cure, but is also
sufficiently tacky to adhere the layer of backing material to the
panel portion prior to activation.
11. A structurally reinforced member as in claim 1 wherein the
reinforcement material and the backing material are substantially
coextensive along the length of the reinforcement member.
12. A structurally reinforced member as in claim 1 wherein the
reinforcement member is contoured to correspond to a surface of the
panel portion.
13. A structurally reinforced panel for an automotive vehicle,
comprising: (a) a metal panel portion; (b) a reinforcement member
having a length and a width, the reinforcement member being a
laminate that includes: i) a reinforcement material selected from
an epoxy-based material, an ethylene-based polymer, or a mixture
thereof, the reinforcement material being layered upon panel
portion; and ii) a backing material formed of layer of metal having
a metal rib extending along the length of the reinforcement member,
the backing material layered upon a surface of the reinforcement
material wherein the length is at least twice the width and wherein
the panel portion is an exterior panel of the automotive
vehicle.
14. A structurally reinforced member as in claim 13 wherein the
reinforcement material is a two-component material that activates
to cure upon exposure of a first component to a second
component.
15. A structurally reinforced member as in claim 13 wherein the
reinforcement material is a heat activatable material that
activates to foam and cure upon exposure to a temperature
experience in an e-coat or paint curing oven.
16. A structurally reinforced member as in claim 13 wherein the rib
is roll formed to have an arc and wherein the backing material is
at least partially formed of aluminum or steel and wherein the
panel portion is part of a automotive vehicle panel selected from a
quarter panel, a side panel, a hood panel, a trunk panel or a door
panel.
17. A structurally reinforced member as in claim 13 wherein the
length is between about 30 cm and about 100 cm and wherein the
layer of reinforcement material has a thickness between about 3 mm
and about 10 mm and wherein the reinforcement material and the
backing material are substantially coextensive along the length of
the reinforcement member.
18. A structurally reinforced member as in claim 13 wherein the
reinforcement material is activatable to foam and cure, but is also
sufficiently tacky to adhere the layer of backing material to the
panel portion prior to activation.
19. A structurally reinforced member as in claim 13 wherein the
reinforcement member is contoured to correspond to a surface of the
panel portion.
20. A structurally reinforced panel for an automotive vehicle,
comprising: (a) a metal panel portion; (b) a reinforcement member
having a length and a width, the reinforcement member being a
laminate that includes: i) a reinforcement material selected from
an epoxy-based material, an ethylene-based polymer, or a mixture
thereof, the reinforcement material being layered upon panel
portion; and ii) a backing material formed of layer of metal having
a roll formed metal rib extending along the length of the
reinforcement member, the backing material being shaped as an
elongate panel that is layered upon a surface of the reinforcement
material. wherein the length is at least 10 times the width;
wherein the panel portion is an exterior panel of a door of the
automotive vehicle; wherein the reinforcement material is a two
component material that activates to cure upon exposure of a first
component to a second component, the first component including an
epoxy resin and the second component including an amine.
21. A structurally reinforced member as in claim 20 wherein the rib
is roll formed to have an arc and wherein the backing material is
at least partially formed of aluminum or steel and wherein the
length is between about 30 cm and about 100 cm and the layer of
reinforcement material has a thickness between about 3 mm and about
10 mm and wherein the reinforcement material and the backing
material are substantially coextensive along the length of the
reinforcement member and wherein the reinforcement member is
contoured to correspond to a surface of the panel portion.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to a structurally
reinforced panel of an automotive vehicle or other article of
manufacture, and more particularly to a panel structurally
reinforced with a member formed of a reinforcement material and a
backing material.
BACKGROUND OF THE INVENTION
[0002] For many years the transportation industry has been
concerned with designing structural members that do not add
significantly to the weight of a vehicle. At the same time,
automotive applications require structural members capable of
providing reinforcement to targeted portions of the vehicle such as
vehicle panels. It is known to apply a layer of heat activated
matrix material along with a fibrous reinforcement material to
panels of automotive vehicles for structurally reinforcing the
panels. However, the fibrous materials that are used to achieve
reinforcement of the panels can be expensive. Additionally, desired
levels of reinforcement may not be achieved with the presently used
fibrous materials. Thus, there is a need to replace the presently
used fibrous material with a lower cost material that can be
applied to vehicle panels along with a reinforcement material
wherein the replacement material provides sufficient reinforcement
to the panels, the reinforcement material or both.
SUMMARY OF THE INVENTION
[0003] The present invention satisfies one or more of these needs
by providing a structurally reinforced panel and a method of
manufacturing the same.
[0004] Accordingly, the present invention provides a structurally
reinforced panel that includes a reinforcement material, a panel
portion and a backing material disposed thereon. The backing
material is typically a layer of material that includes at least
one rib. In one preferred embodiment, the backing material is a
metal layer with a roll formed rib.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] 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:
[0006] FIG. 1 is an exploded perspective view of a structurally
reinforced panel of an automotive vehicle according to an exemplary
aspect of the present invention.
[0007] FIG. 2 is a perspective view of the structurally reinforced
panel of FIG. 1 after formation thereof.
[0008] FIG. 3 is a sectional view of the structurally reinforced
panel of FIG. 2 taken along line 3-3.
[0009] FIG. 4 is a sectional view of an alternative structurally
reinforced panel according to an exemplary aspect of the present
invention.
DETAILED DESCRIPTION OF THE INVENTION
[0010] The invention relates to a structurally reinforced panel of
an article, such as an automotive vehicle, a household or
industrial appliance, furniture, storage containers or the like,
and to a method of forming the panel. More particularly, the
present invention relates to a reinforced panel of an automotive
vehicle that includes a panel portion, a layer of reinforcement
material applied (e.g., attached or otherwise bonded) to at least
part of a surface of the panel portion and a layer of backing
material positioned (e.g., applied or laminated) upon the
reinforcement material, the panel portion or both. Preferably, the
reinforcement material of the panel portion is a high strength to
weight reinforcement material.
[0011] Referring to FIGS. 1 and 2, there is illustrated an
exemplary embodiment of a structurally reinforced panel 10. The
panel 10 includes a reinforcement member 12 applied to a panel
portion 14 (e.g., of a vehicle door). In the embodiment shown, the
reinforcement member 12 is composed of a layer 16 of reinforcement
material, which is applied to at least a part of a surface 22 of
the panel portion 14, and a layer 24 of backing material disposed
upon the layer 16 of reinforcement material.
[0012] As used herein, the term "panel portion 14" is broadly meant
to encompass any component providing a surface 22 suitable for
application of the layer 12 of composite material thereto.
Preferably, the panel portion 14 is metal and includes a surface
opposite the surface 22 to which the layer 12 of composite material
is applied. For automotive applications, the panel portion 14 may
be chosen from a variety of components of an automotive vehicle.
Examples include components of a vehicle frame, components of a
vehicle body or the like. In one highly preferred embodiment, the
panel portion 14 is at least part of a body panel of an automotive
vehicle wherein the body panel includes a surface that is visible
from the outside of the vehicle and wherein that surface is
opposite the surface 22 to which the reinforcement member 12 is
applied. Examples of such panels include front and rear quarter
panels, side panels, hood panels, trunk panels, door panels or the
like.
Reinforcement Material
[0013] The layer 16 of reinforcement material may be configured in
a variety of shapes, designs, or thicknesses corresponding to the
dimensions of the selected panel portion 14 of the vehicle or
otherwise configured as desired. The layer 16 of reinforcement
material may be composed of one substantially homogeneous material
or layer or multiple different materials or layers. Preferably, at
least a portion of the reinforcement material is expandable,
foamable, curable or a combination thereof.
[0014] The reinforcement material is preferably selected so as to
be activatible under a desired condition to soften (e.g, melt),
expand, foam or otherwise change states such that the reinforcement
material can wet, and preferably bond to adjacent surfaces (e.g.,
the surfaces provided by the layer 24 of backing material, the
panel portion 14 or a combination thereof). In one embodiment, the
reinforcement material is also selected to cure during or after
activation and, upon or after cure, form a relatively low density,
low weight material with high strength characteristics such as high
stiffness for imparting structural rigidity to a reinforced region
of the panel portion 14. In a preferred embodiment, the
reinforcement material has a post-cure glass transition temperature
that is greater than any temperatures to which the reinforcement
material may be exposed while in its intended environment of use
(e.g., in an automotive vehicle). Exemplary glass transition
temperatures may be greater than about 50 degrees Celcius and more
preferably greater than about 70 degrees Celsius. Other desired
characteristics of the reinforcement material might include good
adhesion retention and degradation resistance particularly in the
presence of corrosive or high humidity environments.
[0015] A number of reinforcement materials may be used to form the
layer 16. The reinforcement material may be a thermoplastic, a
thermoset or a blend thereof. According to one embodiment, the
reinforcement material is provided as an epoxy-based material, an
ethylene-based polymer, or a mixture thereof, which when compounded
with appropriate ingredients (typically a blowing agent, a curing
agent, and perhaps a filler), typically expands, cures or both in a
reliable and predictable manner upon the application of heat or
another activation stimulus.
[0016] Thus, according to one embodiment, the reinforcement
material is a heat-activated, epoxy-based resin having foamable
characteristics upon activation through the use of heat typically
encountered in an e-coat or other paint oven operation. Preferably,
the epoxy reinforcement material is such that upon being heated, it
structurally bonds to adjacent surfaces. From a chemical standpoint
for a thermally-activated material, such reinforcement material is
usually initially processed as a thermoplastic material before
curing. After curing, the reinforcement material typically becomes
a thermoset material that is fixed and incapable of any substantial
flowing. Examples of preferred formulations that are commercially
available include those available from L&L Products, Inc. of
Romeo, Mich., under the designations L-5204, L-5206, L-5207,
L-5208, L-5209, L-5214, L-5222 and L-8000.
[0017] The layer 16 of reinforcement material may be formed using a
variety of processing techniques, machines or the like. Possible
processing techniques for the preferred materials include injection
molding, blow molding, thermoforming, extrusion with a single or
twin screw extruder or extrusion with a mini-applicator extruder.
In a preferred embodiment, the layer 16 of reinforcement material
is extruded using a twin-screw extruder and with the resulting
layer 16 having a substantially continuous thickness or a variable
thickness. Though preferred reinforcement materials are disclosed
other suitable art disclosed reinforcement materials may be used in
conjunction with the present invention. The choice of the
reinforcement material used will be dictated by performance
requirements and economics of the specific application and
requirements. Examples of other possible reinforcement materials
include, but are not limited to, polyolefin materials, copolymers
and terpolymers with at one monomer type an alpha-olefin,
phenol/formaldehyde materials, phenoxy material, polyurethane
materials with high glass transition temperatures (including
polyureas), and mixtures or composites (optionally including solid
or porous metals). See also, U.S. Pat. Nos. 5,766,719; 5,755,486;
5,575,526; 5,932,680 (incorporated herein by reference).
[0018] Generally speaking, exemplary automotive vehicle
applications may utilize technology and processes such as those
disclosed in U.S. Pat. Nos. 4,922,596, 4,978,562, 5,124,186 and
5,884,960, commonly owned U.S. Pat. Nos. 6,467,834, 6,482,486,
6,620,501, 6,634,698, 6,419,305, 6,471,285, 6,561,571 and
particularly co pending U.S. application Ser. No. 09/459,756 filed
Dec. 10, 1999, all of which are expressly incorporated by
reference.
[0019] In applications where the reinforcement material is a heat
activated material, such as when a thermally melting, expanding, or
foaming material is employed, an important consideration involved
with the selection and formulation of the material can be the
temperature at which the material activates, cures or both. In most
applications, it is undesirable for the material to activate at
room temperature or the ambient temperature in a production or
assembly environment. For automotive applications, it may be
desirable for the reinforcement material to activate at higher
processing temperatures, such as those encountered in an automobile
assembly plant, when the reinforcement material is processed along
with the automobile components at elevated temperatures. Exemplary
temperatures encountered in an automobile assembly body shop oven
may be in the range of 148.89.degree. C. to 204.44.degree. C.
(300.degree. F. to 400.degree. F.), and paint shop oven temps are
commonly about 93.33.degree. C. (215.degree. F.) or higher. If
needed, for foaming or expanding type reinforcement materials,
various blowing agent activators can be incorporated into the
composition to cause expansion at different temperatures outside
the above ranges.
[0020] Although many reinforcement materials may be heat activated,
other reinforcement materials that are activated by another stimuli
and are capable of bonding also can be used. Without limitation,
such reinforcement material may be activated by alternative stimuli
such as, pressure, chemicals, or by other ambient conditions.
[0021] In one desirable embodiment, the reinforcement material is
provided as a two component adhesive or reinforcement material as
that term is used in the art. As a two component material, the
reinforcement material would typically be formed by combining an
A-side (i.e., a polymeric or resin component) with a B-side (i.e.,
an activating and or curing component). Typically, although not
required, the A-side is maintained separate from the B-side until
shortly before (.e.g, within an hour or more, within 10 minutes or
within 1 minute) application to the panel portion, the backing
material or both. Examples of A-side materials can include
epoxy-based materials, EVA based materials, polyurethane based
materials, combinations thereof or the like. Examples of B-side
materials can include amines, acid, isocyanates, combinations
thereof or the like.
[0022] The two component material is typically designed to cure
(e.g., partially or fully cure) upon addition of the A-side to the
B-side. The material may be configured to cure within any amount of
time after such addition. Typically, however, the material cures
within one hour, more typically within 20 minutes and even more
typically within 5 minutes of addition of the A-side to the
B-side.
[0023] The reinforcement material may be provided in a variety of
shapes and configurations. Thus, the layer of reinforcement
material may be square, circular, round, elliptical, geometric,
non-geometric, rectangular, combinations thereof or any other shape
desired. In the particular embodiment illustrated, the layer 16 of
reinforcement material is formed as a strip having a length
(L.sub.1) and a width (W.sub.1). For that particular embodiment,
the length (L.sub.1) is typically at least twice the width
(W.sub.1), more typically at least 5 times the width (W.sub.1) and
even more typically 10 times the width (W.sub.1). As such, the
length (L.sub.1) is typically between about 10 cm or less and about
200 cm or more, more typically between about 30 cm and about 100 cm
and even more typically between about 40 cm and about 70 cm. The
width (W.sub.1) is typically between about 0.5 cm and about 15 cm,
more typically between about 1.0 cm and about 7 cm and event more
typically between about 2 cm and about 4 cm. The layer 16 of
reinforcement material also has a thickness (T.sub.1) that is
typically between about 5 mm or less and about 20 mm or greater,
more typically between about 3 mm and about 10 mm and even more
typically between about 4 mm and about 8 mm.
Backing Material
[0024] The backing material may be chosen from a variety of
materials. For example, and without limitation, the backing
material may be formed of metal foils, metal sheets, metal screens
or the like. As alternative examples, the backing material may be
formed of polymeric (e.g., thermoplastic) films, sheets or mesh. In
still other alternative embodiments, the backing material may be
formed of cellulose fiber material such as impregnated or
non-impregnated paper, wood or the like. The backing material may
also be formed of filament, fibrous or fabric material, for
example, woven or unwoven strands, fibers, filaments or the like of
cotton, fiberglass, nylon, carbon, aramid or other materials. It is
also contemplated that combinations of each of these materials may
be employed as the backing material or multiple separate backing
materials may be employed and may be the same or different.
[0025] According to a preferred embodiment, the backing material is
a metal layer. The metal layer may be partially or substantially
entirely formed of metals such as aluminum, steel (e.g., galvanized
or galvannealed steel), iron, titanium, magnesium, zinc,
molybdenum, brass, cobalt, nickel, copper, vanadium, chromium,
manganese, platinum, gold, silver, combinations thereof or the like
combinations thereof or the like.
[0026] It is typically preferable for backing material to include
at least one rib and potentially a plurality (e.g., 2, 3, 4, 5 or
more) of ribs. Such rib or ribs may be integrally formed with the
backing material or may be separately formed and attached thereto.
For example, the rib or ribs may be integrally molded or extruded
as part of the backing material, particularly when the backing
material and the rib are formed of metal or polymeric materials. As
another example, metal forming techniques such as stamping or other
techniques may be employed.
[0027] In the embodiment of FIGS. 1 and 2, the layer 24 of backing
material is a layer of metal with a rib 30 roll formed into the
layer. As such, the rib 30 is an arched portion of the layer 24
that, as shown, is generally U-shaped, but may be V-shaped or
otherwise shaped as desired. The layer 24 typically has a thickness
between about 0.5 mm or less and about 10 mm or greater, more
typically between about 1 mm and about 5 mm and event more
typically between about 2 mm and about 4 mm.
[0028] The layer 24 of backing material is also shown as a strip
having a length (L.sub.2) and a width (W.sub.2). The length
(L.sub.2) and width (W.sub.2) of the layer 24 typically correspond
to (i.e., are within about 2 centimeters of) the length (L.sub.1)
and width (W.sub.1) of the layer 24 of reinforcement material,
although not required. Such correspondence is seen in the member 12
of FIGS. 1 and 2. Thus, the preferred length (L.sub.2) and width
(W.sub.2) of the layer 24 of backing material and a preferred
length (L) and width (W) of the member 12 and the ratios of length
to width are typically the same as those recited for the length
(L.sub.1) and width (W.sub.1) of the layer 16 of reinforcement
material. Preferably, although not required, the one or more ribs
extend substantially the entire length of the layer 24 of backing
material.
Manufacture
[0029] Generally speaking, the member 12 is applied to the panel
portion 14 by applying (e.g., contacting) the layer 16 of
reinforcement material to a surface of the panel portion 14 and
applying (e.g., contacting) the layer 24 of backing material to the
reinforcement material. This may be done in any order. According to
one preferred protocol, however, the layer 16 of reinforcement
material is applied to the layer 24 of backing material to form the
member 12 and then the member 12 is applied to the panel portion
14. According to another preferred embodiment, the layer 16 of
reinforcement material is applied to the surface 22 of the panel
portion 14 and the layer 24 of backing material is applied to the
layer 16 of reinforcement material.
[0030] In one preferred embodiment, the layer 24 of backing
material is positioned (e.g., laminated) as desired upon a first
side of the layer 16 of the reinforcement material and a second
side of the layer 16 of reinforcement material is positioned (e.g,
laminated) upon the surface 22 of the panel portion 14. Preferably,
the reinforcement material is sufficiently tacky such that the
layer 16 of reinforcement material can adhere to the layer 24 of
backing material, the surface 22 of the panel portion 14 or both.
In that instance, a pressure or force is typically applied to the
layer 24 of backing material, the layer 16 of reinforcement
material, the panel portion 14, or a combination thereof, urging
the layer 16 of backing material and/or the surface 22 of the panel
portion 14 into intimate contact with the layer 16 of reinforcement
material. In alternative embodiments, particularly when the
reinforcement material is not tacky, it is contemplated that
mechanical fasteners, additional adhesive or other fastening
mechanisms may be employed to at least temporarily attach the
reinforcement material to the backing material the panel portion or
both.
[0031] Release paper may be applied (e.g., laminated) upon the
layer 16 of reinforcement material preferably while the layer 16 of
reinforcement material is still in a tacky potentially
pre-activated state. Preferably, a side of the layer 16 of
reinforcement material covered by the release paper remains
protected and at least partially tacky such that the release paper
may be removed and the layer 16 of reinforcement material together
with the layer 24 of backing material may be applied (e.g., adhered
and/or laminated) to the panel portion 14 as the member 12.
[0032] The member may be applied generally as desired to the panel
portion 14. Preferably, however, the member is applied to panel
portions to reduce deformation in selected areas. For targeting
certain areas or for properly fitting the member upon a panel
portion, the member may be contoured (e.g. curved or otherwise
shaped) to correspond any contours of the panel portion 14. For
example, a door panel or other panel of an automotive vehicle may
be curved (e.g., outwardly curved) and the member may be
correspondingly curved to allow the member to be more easily
attached (e.g., adhered) to the panel.
[0033] The layer 16 of reinforcement material may be applied to the
panel portion 14, to the backing material or both, in a solid or
semi-solid state. However, the layer 16 may also be applied to the
surface 22 of the panel portion 14 to the backing material or both
in a fluid state using commonly known manufacturing techniques.
Moreover, the reinforcement material may be heated to a temperature
that permits it to flow slightly to aid in wetting the surface 22
of the panel portion 14. Alternatively, the layer 16 may also be
applied by heat bonding/thermoforming or by co-extrusion.
[0034] For forming the reinforced panel 10 of FIGS. 2 and 3, the
reinforcement material may each be activated to flow, expand, foam,
cure or a combination thereof. Activation may be induced by a
variety of stimuli such as moisture, chemicals, heat or the like
and curing may also be induced by a variety of stimuli such as
time, cooling or the like.
[0035] The layer 16 of reinforcement material hardens upon curing
such that the layer 16 can provide added structural integrity to
the panel portion 14. Preferably, the layer 16 of reinforcement
material adheres, and/or reactively bonds to both the surface 22 of
the panel portion 14 and to the layer 24 of backing material upon
curing.
[0036] In one embodiment, the layer 16 of reinforcement material,
is activated during an automotive bake cycle. In such an instance,
it is preferable that the layer 16 of reinforcement material
maintains a substantially high viscosity during the bake cycle such
that the layer 16 substantially maintains its location between the
layer 24 of backing material and the panel portion 14. In another
embodiment, particularly when a two component material is employed,
the layer 24 of reinforcement material cures upon application to
the layer 24 of backing material, the surface 22 of the panel
portion 14 or both (e.g., upon addition of the A-side to the
B-side).
Additional or Alternative Embodiments
[0037] It is contemplated that the, a buffer layer may be applied
between the reinforcement member and the panel portion. An example
of this is illustrated in FIG. 4. As can be seen, a layer 40 of
buffer material is interposed between the reinforcement member 12
and the panel portion 14.
[0038] The layer 40 of buffer material is preferably a material
that has elastomeric or compliant properties. The buffer material
may include one or any combination of the following components: one
or more polymer components (e.g., elastomers, plastomers, rubbers,
plastics or the like), one or more fillers or additives and one or
more curing agents or adhesives. Other components may be included
in the buffer material as well such as component for imparting
surface tack, magnetism or the like to the material. Moreover, the
buffer material may be water-based, solvent-based, substantially
solid or otherwise. Preferably, the components of the buffer
material are chosen such that the buffer material is capable of
viscoelastic recovery during and after installation of the member
12 to the panel portion 14.
[0039] Typically the polymer components will include at least one
elastomer. Exemplary elastomers include natural and synthetic
isoprenes, propylenes, styrene butadiene copolymers, terpolymers of
ethylene, isobutene isoprene polymers, butadiene copolymers,
nitrile butadiene copolymers, chlorosulphonated polyethylenes,
polysiloxanes, polyesters, polyisobutylenes fluorinated hydrocarbon
or the like. In one preferred embodiment, the polymer component is
at least partially composed of an acrylic elastomer such as an
acrylonitrile butadiene terpolymer. In another preferred embodiment
the polymer component is at least partially composed of a styrene
butadiene rubber. In highly preferred embodiments, the elastomer of
the buffer material is carboxylated for assisting the buffer
material in adhering to adjacent materials, reacting with adjacent
materials or both.
[0040] Advantageously, the buffer material is compliant with
respect to the reinforcement material during activation, cure or
both of the reinforcement material. Such compliance allows the
reinforcement material to expand, contract or both while the buffer
material absorbs stress that might otherwise be exerted upon the
panel portion 14. In this manner, the buffer material assists in
minimizing any deformation of the panel portion 14 that might
otherwise be caused by the expansion or contraction of the
reinforcement material. As an additional advantage, use of the
buffer material disclosed herein only minimally lessens or does not
lessen the reinforcement ability of the reinforcement material. For
further explanation of the buffer layer 40 and methods of applying
the layer, reference may be had to U.S. patent application Ser. No.
10/098,952, titled "Structurally Reinforced Panels", filed Mar. 15,
2002 and incorporated herein by referenced for all purposes. It is
further contemplated within the present invention that the layer 24
of backing material may include a fiberglass woven roving, which is
disclosed in commonly owned U.S. patent application Ser. No.
09/939,152, also titled "Structurally Reinforced Panels" and fully
incorporated herein by reference for all purposes.
[0041] Additionally it is contemplated that multiple members may be
applied to a single panel. In such an embodiment, the members would
typically be spaced apart upon the panel portion to maximize the
ability of the members to reinforce the panel portion.
[0042] Unless stated otherwise, dimensions and geometries of the
various structures depicted herein are not intended to be
restrictive of the invention, and other dimensions or geometries
are possible. Plural structural components can be provided by a
single integrated structure. Alternatively, a single integrated
structure might be divided into separate plural components. In
addition, while a feature of the present invention may have been
described in the context of only one of the illustrated
embodiments, such feature may be combined with one or more other
features of other embodiments, for any given application. It will
also be appreciated from the above that the fabrication of the
unique structures herein and the operation thereof also constitute
methods in accordance with the present invention.
[0043] 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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