U.S. patent application number 11/086931 was filed with the patent office on 2005-09-29 for structural foam.
This patent application is currently assigned to L&L Products, Inc.. Invention is credited to Bieber, Serge, Bourdin, Jean Philippe, Le Gall, Eric, Sheldon, Simon.
Application Number | 20050212332 11/086931 |
Document ID | / |
Family ID | 9911134 |
Filed Date | 2005-09-29 |
United States Patent
Application |
20050212332 |
Kind Code |
A1 |
Sheldon, Simon ; et
al. |
September 29, 2005 |
Structural foam
Abstract
A structural reinforcement for a hollow member comprising a
rigid reinforcing member having a shape that substantially conforms
to the cross section of the section of the hollow member to be
reinforced with an expandable adhesive material over at least a
portion of the surface of the rigid reinforcing member sufficient
to bond the reinforcing member to at least two nonparallel internal
surfaces of the structure.
Inventors: |
Sheldon, Simon; (Grantham,
GB) ; Le Gall, Eric; (Strasbourg, FR) ;
Bourdin, Jean Philippe; (Obernai, FR) ; Bieber,
Serge; (Haegen, FR) |
Correspondence
Address: |
DOBRUSIN & THENNISCH PC
29 W LAWRENCE ST
SUITE 210
PONTIAC
MI
48342
US
|
Assignee: |
L&L Products, Inc.
Romeo
MI
|
Family ID: |
9911134 |
Appl. No.: |
11/086931 |
Filed: |
March 22, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11086931 |
Mar 22, 2005 |
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10869662 |
Jun 16, 2004 |
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6905745 |
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10869662 |
Jun 16, 2004 |
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10008505 |
Nov 8, 2001 |
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6777049 |
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Current U.S.
Class: |
296/203.01 ;
296/34 |
Current CPC
Class: |
B62D 29/002 20130101;
Y10T 428/24198 20150115; Y10T 428/24182 20150115; Y10T 428/1355
20150115; Y10T 428/1376 20150115; B62D 21/15 20130101; Y10T 428/28
20150115; B62D 25/00 20130101; Y10T 428/1324 20150115; Y10T
428/24149 20150115; Y10T 428/13 20150115; Y10T 428/233 20150115;
Y10T 428/24322 20150115 |
Class at
Publication: |
296/203.01 ;
296/034 |
International
Class: |
B62D 033/00; B60N
002/00; B60N 003/00; B60J 007/00; B60R 027/00; B60K 037/00 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 20, 2001 |
GB |
0106911.1 |
Claims
1-24. (canceled)
25: A method of reinforcing a structure of an article of
manufacture, the method comprising: providing a rigid pre-formed
structural reinforcing member formed of metal or plastic; locating
an unfoamed expansive adhesive material upon one or more surfaces
of the structural reinforcing member; and positioning the
reinforcing member within a cavity of the structure of the article
of manufacture such that the adhesive material approaches an
internal surface of the structure; activating the adhesive material
to expand and adhere to the internal surface of the structure.
26: A method as in claim 25 wherein the structure of the article of
manufacture is at least partially formed of aluminum.
27: A method as in claim 26 wherein the reinforcing member produces
a sound deadening effect by blocking paths of in the cavity.
28: A method as in claim 27 wherein the article of manufacture is
selected from a household appliance, an architectural structure, an
automotive structure, an aerospace structure or a marine
structure.
29: A method as in claim 25 wherein the structural reinforcing
member further comprises at least one locator attached to and
moulded with the structural reinforcing member, the at least one
locator assisting in locating the member within the hollow
structural member when said structural reinforcing member is placed
within said structure prior to activation of said material.
30: A method as in claim 29 in which said at least one locator is a
lug.
31: A method as in claim 25 wherein i) the expandable material can
be activated at a temperature of a curing step in an electrocoat
process; ii) the reinforcing member is an injection molded plastic
and has a cellular, honeycomb or ribbed internal structure; iii)
the reinforcing member is made from filled polyamide in which the
filler is selected from glass fibre or carbon fibre; iv) the
expandable adhesive material includes an epoxy-based resin; v) the
expandable material is applied over part of each of the top and
bottom and the sides of the reinforcing member.
32: A method as in claim 25 wherein the reinforcing member is made
from a thermosetting resin.
33: A method as in claim 25 wherein the expandable material expands
at from 130.degree. C. to 150.degree. C.
34: A method of reinforcing a structure of an automotive vehicle,
the method comprising: providing a rigid pre-formed structural
reinforcing member, wherein including: i) provision of the member
includes forming the reinforcing member using a technique selected
from injection moulding or extrusion; locating an unfoamed
expansive adhesive material upon one or more surfaces of the
structural reinforcing member; and positioning the reinforcing
member within a cavity of the structure of the automotive vehicle
such that the adhesive material approaches an internal surface of
the structure; activating the adhesive material to expand and
adhere to the internal surface of the structure.
35: A method as in claim 34 wherein the reinforcing member assists
in preventing point mobility, lozenging or both.
36: A method as in claim 34 wherein the structure includes a floor
section at the base of a rear door pillar of the vehicle and the
reinforcing member resists deformation of upward bending of the
floor section in the event of a rear vehicle impact.
37: A method as in claim 34 wherein: i) the expandable material can
be activated at a temperature of a curing step in an electrocoat
process; ii) the reinforcing member is an injection molded plastic
and has a cellular, honeycomb or ribbed internal structure; iii)
the reinforcing member is made from filled polyamide in which the
filler is selected from glass fibre or carbon fibre; iv) the
expandable adhesive material includes an epoxy-based resin; v) the
expandable material is applied over part of each of the top and
bottom and the sides of the reinforcing member.
38: A method of reinforcing a hollow structure of an automotive
vehicle, the method comprising: providing a rigid plastic
pre-formed structural reinforcing member, wherein: i) providing the
reinforcing member includes injection molding the reinforcing
member to have a shape that substantially conforms to a
cross-section of the hollow structure wherein the reinforcing
member is formed to include holes suitable for drainage of water;
locating an unfoamed expansive adhesive material upon one or more
surfaces of the structural reinforcing member, wherein: i) location
of the unfoamed expansive adhesive material upon the one or more
surfaces is accomplished by a process selected from overmoulding,
extrusion or two-shot injection moulding; and positioning the
reinforcing member within a cavity of the structure of the
automotive vehicle such that the adhesive material approaches one
or more internal surfaces of the structure, wherein: i) the size of
the reinforcing member including the expandable material is such
that there is a clearance of not more than 1 cm between the
reinforcing member and the one or more internal surfaces of the
hollow structural member; ii) the structure is a portion of the
frame of the automotive vehicle; applying an electrocoat to the
structure including the one or more internal surface of the
structure; activating the adhesive material to expand and adhere to
the one or more internal surfaces of the structure including: i)
bonding the reinforcing member to at least two non parallel
internal surfaces of the structure.
39: A method as in claim 38 wherein the clearance is 3 to 10
millimeters.
40: A method as in claim 39 wherein the reinforcing member includes
lugs molded as part of the reinforcing member.
41: A method as in claim 38 wherein reinforcing member assists in
preventing point mobility, lozenging or both.
42: A method as in claim 38 wherein the structure includes a floor
section at the base of a rear door pillar of the vehicle and the
reinforcing member resists deformation of upward bending of the
floor section in the event of a rear vehicle impact.
43: A method as in claim 42 wherein: i) the expandable material can
be activated at a temperature of a curing step in an electrocoat
process; ii) the reinforcing member is an injection molded plastic
and has a cellular, honeycomb or ribbed internal structure; iii)
the reinforcing member is made from filled polyamide in which the
filler is selected from glass fibre or carbon fibre; iv) the
expandable adhesive material includes an epoxy-based resin; v) the
expandable material is applied over part of each of the top and
bottom and the sides of the reinforcing member.
44: A method as in claim 43 wherein the rigid injection molded
plastic pre-formed structural reinforcing member extends along a
length of the reinforcing member and wherein the reinforcing member
comprises internal ribbing.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to reinforcing materials and
in particular to reinforcing materials that can be provided in
hollow cross-sectional members particularly to provide
reinforcement to improve the structural integrity of articles.
BACKGROUND OF THE INVENTION
[0002] The trends in motor vehicle design are towards lighter
vehicles to improve fuel consumption. At the same time, auto
manufacturers continue to demand more rigorous structural
performance standards. The use of lighter materials such as
aluminum to produce the hollow cross-sectional members that are
used as vehicle sub frames has lead to the desire for additional
reinforcement. There is a need for reinforcement in various
locations in the vehicle structure including the sub frame and
upper structure and the form of reinforcement required can vary
from one location in the vehicle to another and from vehicle to
vehicle. The present invention therefore improves the strength of
vehicles structures made from existing materials and enables
vehicle structures based on lighter materials to satisfy safety
requirements they are otherwise unable to satisfy.
[0003] The electrocoat process used in vehicle manufacture is a
process in which the vehicle structure is passed through a bath of
anticorrosion fluid and the vehicle is used as an electrode whereby
an anticorrosion coating is deposited from the fluid onto the
vehicle structure by electrolysis. The invention further provides a
system whereby reinforcement can be provided whilst ensuring
effective provision of an anti-corrosion coating on the inner
surface of the hollow cross-sectional member by the electrocoat
process.
[0004] There are four main types of applications where structural
reinforcement is desired in vehicles. In one, control over vehicle
body deformation is attractive for assisting in accident
management. In another, it is desirable for increased energy
absorption to enhance performance after yield of a structure. The
reduction of flexing or body movement in the vehicle structure
particular to improve durability and reduce stress effects and
point mobility issues requiring the reduction of resonance by the
provision of stiffening. The need for reinforcement is present
irrespective of the materials that are used to produce the vehicle
structure and the need varies from material to material according
to the nature of the reinforcement that is being provided. The
reinforcing parts can also reduce the noise created by the motion
of a vehicle by having a sound deadening effect as a result of
blocking air paths in cavities.
[0005] It is known to provide longitudinal reinforcing structures
within the hollow cross sections of vehicles. For example, PCT
Publication WO97/43501 provides a beam, which can be mounted within
the cross section to provide reinforcement along one axis in a
hollow structure. The beam is provided with an expandable adhesive
on two surfaces, which can be foamed upon heating to bond the beam
to two opposed walls of the cross section. This technique is not
suitable for use in an electrocoat process commonly encountered in
automotive applications. Furthermore, the beam will only provide
significant reinforcement along the axis of the beam. In WO97/43501
the beam with foamable material on opposed surfaces is placed in
the cavity and subsequently foamed under the action of heat. This
will result in uneven foaming and to non-uniform foam structures
since on the underside the foam must raise the weight of the beam
whereas expansion on the topside is free.
[0006] It is also known to provide foamable plastic mouldings
within the hollow cross sections which can be foamed upon
application of heat, such as is provided by the baking step in the
electrocoat process, to provide a foamed baffle that fills the
cross-section to provide sound adsorption. Such systems are
described in European patent applications 0383498 and 0611778. The
foam baffle provides sound deadening and vibration resistance. In
these systems the entire insert is foamable and it is proposed that
the foamable material be chosen so that it will foam during the
baking process, which follows the electrocoat process typically
used in vehicle manufacture to provide resistance to metal
corrosion. The materials of these patents are not however
reinforcing materials but are used to provide acoustic baffles and
seals.
[0007] In the electrocoat process a vehicle structure is immersed
in a bath of coating fluid from which an anticorrosion coating is
deposited on the metal by electrolysis. The vehicle metal structure
is subsequently heated to bake the coating on the metal. The
electrocoat process is typically applied to complete vehicle
structures in which hollow sections have been capped. Accordingly
reinforcing structures are preferably provided within hollow
sections prior to the electrocoat. It is therefore important that
the reinforcing structure have minimal impact on the operation and
efficiency of the electrocoat process.
[0008] Where reinforcing materials have been provided they have
either been stuck to the metal structure prior to subjecting the
vehicle structure to the electrocoat process or have been provided
after the electrocoat process. The former technique has the problem
that it is not possible to perform the electrocoat over the entire
surface, which can lead to local areas of corrosion. The latter
technique is cumbersome and requires the provision of fastening
means after electrocoating, which can damage the electrocoat and
again lead to local areas of corrosion.
[0009] There is therefore a need to provide structural
reinforcement for the hollow cross-sections of vehicles, which is
easily supplied, works well within the bounds of the electrocoat
process and provides effective reinforcement to the vehicle both
during operation and as crash protection.
[0010] The present invention therefore provides a structural
reinforcement for a hollow member comprising a rigid reinforcing
member having a shape that substantially conforms to the cross
section of the section of the hollow member to be reinforced with
an expandable adhesive material over at least a portion of the
surface of said rigid reinforcing member sufficient to bond the
reinforcing member to at least two non parallel internal surfaces
of the structure.
[0011] In one aspect of the invention, the dimensions of the rigid
reinforcing member and the thickness and nature of the expandable
material are important to the achievement of the desired structural
reinforcement. The exterior shape of the reinforcing member should
conform substantially to the cross section of the section of the
structure it is designed to reinforce. The shape may vary along the
length of the reinforcing member as the dimensions of the cross
section of the structure change. The size of the reinforcing member
including the expandable adhesive material should be such that
there is a small clearance between the extremity of the reinforcing
member and the interior walls of the structure it is to be
reinforced (e.g., the frame of the vehicle) to allow for passage of
the electrocoat fluid. Preferably, the reinforcing member has a
cellular, honeycomb or ribbed internal structure to provide
reinforcement along several different axes.
[0012] In a preferred embodiment the structural reinforcing member
is provided with small lugs, which enable it to stand away from the
interior walls of the sections of the structure to be reinforced.
In this way fastening devices are not required and the area of
contact between the structural reinforcing member and the interior
walls of the structure is minimized. In a preferred embodiment, the
clearance between the extremity of the reinforcing member and the
interior walls of the structure (e.g., frame of the vehicle) must
be wide enough to enable the liquid used in any coating (such as
the electrocoat bath) to flow between the reinforcing member and
the interior walls of the sections of the structure in sufficient
quantity to enable an effective coating (e.g., anti-corrosion
coating) to be deposited. On the other hand, the clearance must not
be too wide since this can result in a lack of rigidity in the
structure when the expandable adhesive is foamed to fill the
clearance and bond the structural reinforcing member to the
interior walls of the structure. Preferably, the clearance is no
more than 1 centimeter and is more preferably 3 to 10 millimeters.
The clearance around the whole structure enables a more uniform
foam structure to be obtained.
[0013] The rigid reinforcing member may be made from any suitable
material, for example it may be made of metal or plastic and the
material will be chosen according to the preferred fabrication
method. This in turn is driven by economics and the complexity of
the cross section to be reinforced. Reinforcing members for simple
cross sections may be prepared by extrusion whilst injection
moulding may be required for more complex structures. Metal members
may be produced by stamping and/or forming. Where extrusion is used
the members may be of metal or thermoplastics; where injection
moulding is used thermoplastics are preferred. Polyamides,
particularly glass filled polyamides are suitable materials due to
their high strength to weight ratio. Alternatively injection
moulding or die casting of metal alloys (either densified or
foamed) may be employed. It is preferred that the moulding is
provided with means enabling fluid drainage. For example, holes may
be provided in the moulding to allow the drainage of water, which
may condense in the structure over time.
[0014] The preferred shape and structure of the reinforcing member
will depend upon where it is to be located in the structure and the
function it is to perform. For example, if it is to be located in
the front longitudinal section of a vehicle it will be designed for
crash or impact resistance. On the other hand, it may be designed
to reduce point mobility such as for example at the base of side
and rear pillars. This is particularly important with high-sided
vehicles where the reinforcement potentially can help reduce or
prevent vehicle sway thus reducing metal fatigue. Other
applications include the resistance of deformation of the rear
longitudinal section, in particular to help prevent upward
deformation from certain rear impacts. Other parts of the vehicle
which may be reinforced by the techniques of the present invention
include roof structures, pillars, frame cross members and window
frames particularly rear window frames.
[0015] The expandable adhesive material serves two main functions,
it will expand to fill the space between the reinforcing member and
the interior of the structure to be reinforced and it will also
bond to the interior wall of the structure. Accordingly, expandable
adhesive material means that the material can be activated to both
expand (typically foam) and to act as an adhesive. Activation
therefore enables the expandable material to expand and fill a gap
between the reinforcing member and a hollow structure it is
designed to reinforce and to bond to the internal surface of the
hollow structure. Accordingly the expandable adhesive must expand
at the desired temperature and be sufficiently adhesive to firmly
bond the reinforcing member inside the vehicle structure. Once
foamed it should be sufficiently strong that it does not materially
detract from the overall reinforcing effect provided.
[0016] Whilst it is not essential it is preferred that prior to
activation, the expandable adhesive material is dry and not tacky
to the touch. It is preferred that the expandable material is not
tacky to the touch since this facilitates shipping and handling and
prevents contamination. Examples of preferred foamable materials
include foamable epoxy-base resins and examples of such materials
are the products L5206, L5207, L5208 and L5209, which are
commercially available from L & L Products of Romeo, Mich. USA,
and the Betacore Products BC 5204, 5206, 5205 and 5208 available
from Core Products, Strasbourg, France. The product should be
chosen according to the rate of expansion and foam densities
required. It is further preferred that it expand at the
temperatures experienced in the electrocoat baking oven, typically
130.degree. C.-150.degree. C.
[0017] The expandable adhesive material should be applied to at
least a portion of the surface of the rigid reinforcing member that
will be adjacent to an interior surface of the section of the
structure that is to be reinforced. It is preferred that the
foamable material be applied over at least part of all the surfaces
of the reinforcing member that are adjacent to the interior surface
of the section. This will depend upon the shape of the section to
be reinforced but it should be present so that it provides adhesion
to two non-parallel surfaces to give rigidity in at least two
dimensions. It is preferred that the foamable material be applied
over at least part of each of the top and bottom and the sides of
the reinforcing member. In this way when the material is foamed it
can expand to fill the gap around the entire surface of the
reinforcing member that is adjacent to the interior walls. The
expandable material may be applied to the rigid reinforcing member
by bonding a strip of the material to the member, by extrusion
coating or by injection moulding. Where the reinforcing member is
made by injection moulding the expandable material may be applied
by over-moulding or two shot injection moulding. The material
should however be applied under conditions such that no foaming
takes place.
[0018] It is preferred that the reinforcing member coated with the
expandable material is located within the hollow member that it is
designed to reinforce in a manner that provides a clearance between
the external surface of the coated member and the internal surface
of the hollow member. This allows for the passage of coating fluid
between the member and the internal surface and also enables a
uniform expansion of the foam around the member to provide more
uniform reinforcement. Accordingly in a preferred process for
providing reinforcement within hollow structures such as a vehicle
frame, moulded reinforcing members with the layer of foamable
adhesive thereon are installed during assembly of the vehicle
frame. Locating lugs are preferably moulded into the reinforcing
member or the expandable material so that the reinforcing member
sits within the vehicle structure leaving a space between the
member and the interior walls of the cavity to be reinforced, in
this way there is no need for fastening or bonding means to attach
the member to the interior walls. The assembled structure is then
subjected to the electrocoat process in which it is passed through
a bath of coating material and a corrosion resistant coating is
deposited onto the structure by electrolysis. The vehicle structure
is then dried in an oven to provide the final coating and the
expandable adhesive is preferably chosen so that it is activated by
the drying conditions used in the oven employed to bake the coating
on the electrocoat process. In this way the expandable material
will expand under the drying conditions to provide a foam that
fills the space between the member and the interior walls and will
produce a strong bond between the reinforcing member and the
interior wall. Typically the coated structure is dried at around
165.degree. C. for about 20 minutes and accordingly the adhesive
should expand under these conditions. The industry is however
looking to use lower drying temperatures and shorter drying times
and this may influence the choice of expandable adhesive
materials.
[0019] If other components for example bolts are to pass through
the reinforcing members during subsequent assembly care must be
taken to ensure that holes formed in the reinforcing member for the
passage of the bolts are not blocked by the foam as it expands.
[0020] The techniques of the present invention may be used for the
reinforcement of any construction that is based on a hollow frame
structure. Thus, the present invention is not limited to automotive
vehicle applications. The structural reinforcement may be employed
for reinforcing any of a variety of different structures in which a
cavity or wall is available against which the expandable adhesive
material may contact and bond. Examples of such applications
include reinforcements for household appliances, furniture, storage
containers, luggage, seating, building materials or other
architectural structures, aerospace structures, marine structures,
railway structures, or the like. The techniques are particularly
useful in the current trend towards using lighter and sometimes
weaker materials in the production of automobile sub frames where
there is a greater need for reinforcement to compensate for the
eduction in strength of the basic material and yet satisfy the
safety requirements. This is particularly the case with the use of
aluminum for the production of automotive vehicles.
BRIEF DESCRIPTION OF DRAWINGS
[0021] The present invention is illustrated by reference to the
accompanying drawings in which FIG. 1 illustrates a plan view of a
first preferred embodiment of a moulding according to the present
invention that is designed to limit point mobility;
[0022] FIG. 2 illustrates a side view of the moulding in FIG.
1;
[0023] FIG. 3 illustrates a cross-section of the moulding in FIG. 1
showing the interior cellular structure of the moulding of the
present invention;
[0024] FIG. 4 illustrates a plan view of a second preferred
embodiment of the moulding of the present invention that is
suitable for resisting deformation;
[0025] FIG. 5 illustrates the moulding of FIG. 4 in position on the
floor of a vehicle; and
[0026] FIG. 6 illustrates an expanded view of the moulding in FIGS.
4 and 5.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENT
[0027] The present invention is illustrated by reference to the
accompanying drawings in which FIG. 1 shows a moulding according to
the present invention.
[0028] FIG. 1 is of a moulding designed to limit point mobility and
prevent what is known as lozenging. The moulding consists of a
reinforcing member 1 moulded to conform to the cross section of the
front longitudinal section of a vehicle. The reinforcing member
consists of a frame with transverse and longitudinal ribs 2 to
provide compression strength and torsional resistance. The moulding
has been over moulded at the two ends with layers of an expandable
adhesive 3. FIG. 2 is an end elevation of the moulding showing the
lugs 4 which will locate the moulding within the vehicle cross
section. FIG. 3 is a cross section of the moulding shown in FIG. 1
illustrating the cellular structure.
[0029] FIG. 4 shows an alternate form of moulding which is suitable
for resisting deformation particularly in the rear longitudinal
section of a vehicle This moulding is especially useful in the
preventing the floor bending upwards upon a rear impact.
[0030] The moulding shown in FIG. 4 is a polyamide moulding 5,
which is over-moulded in those areas, which are to be in proximity
to the internal surface of the vehicle frame with a foamable
structural foam material 6.
[0031] The moulding is designed to provide reinforcement at the
position where the rear door pillar of the vehicle joins the
vehicle floor frame. FIG. 5 shows the piece in position on the
floor section 7 at the base of the rear door pillar 8 and FIG. 6 is
an expanded view of the moulding lying in position on the floor
section 7.
[0032] When the vehicle assembly is completed it can be passed
through the electrocoat process and when it is heated to bake the
electrocoat coating the foamable structural foam will foam to come
into contact with and to bond to the internal surface of the
vehicle frame. In this way a firmly bound structural reinforcement
is provided which resists upward movement of the floor portion of
the vehicle due to rear impact collision.
* * * * *