초록

A structurally reinforced panel and a method of forming the panel are disclosed. The reinforcement includes a fibrous woven material in a bondable plastic matrix.

대표청구항 ▼

1. A structurally reinforced panel for an article, comprising:(a) a panel; (b) a woven roving, having a weight of less than about 20 ounces per square yard, adjoining said panel; and (c) a matrix material for carrying said woven roving, said matrix material being bonded to said panel, over at least

1. A structurally reinforced panel for an article, comprising:(a) a panel; (b) a woven roving, having a weight of less than about 20 ounces per square yard, adjoining said panel; and (c) a matrix material for carrying said woven roving, said matrix material being bonded to said panel, over at least part of a surface of said panel. 2. A structurally reinforced panel as in claim 1, wherein said woven roving weighs less than 15 ounces per square yard.3. A structurally reinforced panel as in claim 1, wherein said woven roving weighs less than 10 ounces per square yard.4. A structurally reinforced panel as in claim 1, wherein said woven roving weight less than about 8 ounces per square yard.5. A structurally reinforced panel as in claim 1, wherein said matrix material is epoxy-based.6. A structurally reinforced panel as in claim 1, wherein said matrix material is expandable to assist in integrating said woven roving with said matrix material.7. A composite material for reinforcing a panel of an automotive vehicle, comprising:a) a woven roving strip, having a weight of less than about 10 ounces per square yard, a width of between about 2 and about 5 cm and a thickness of greater than about 5 mils; b) an expandable epoxy-based matrix material, thermally activable in a temperature range of about 300° F. to 400° F. for carrying said woven roving, said matrix material being bondable to said panel over at least part of a surface of said panel; and c) a release layer laminated to a side of said matrix material for protecting said side of said matrix material prior to bonding said side of said matrix material to said panel. 8. A composite material as in claim 7, wherein said roving strip weighs less than 15 ounces per square yard.9. A composite material as in claim 7, wherein said roving strip material weighs less than 10 ounces per square yard.10. A composite material as in claim 7, wherein said roving strip weighs less than about 8 ounces per square yard.11. A composite material as in claim 7, wherein said roving strip includes an e-glass.12. A composite material as in claim 7, wherein said roving strip includes an S2-glass.13. A structurally reinforced panel as in claim 1, wherein the woven roving is formed of fiberglass strands and the panel is formed of metal.14. A structurally reinforced panel as in claim 1, wherein the matrix material is selected from an epoxy-based material, an ethylene-based polymer, or a mixture thereof.15. A structurally reinforced panel as in claim 1, wherein the matrix material is an epoxy-based material.16. A structurally reinforced panel for an automotive vehicle, comprising:(a) a metal panel, the metal panel being a part of the automotive vehicle; (b) a fibrous reinforcement material adjoining said panel, wherein: i) the reinforcement material is comprised of a plurality of strips woven together as a sheet; and ii) each of the plurality of strips is formed of several fibers which are grouped together, but which are generally unwoven relative to each other; and (c) a matrix material for carrying said fibrous reinforcement material, said matrix material being bonded to said panel, over at least part of a surface of said panel wherein; i) the matrix material is a heat activated foamable material for assisting in integrating the fibrous reinforcement material with the matrix material. 17. A structurally reinforced panel as in claim 16, wherein the fibers for the fibrous reinforcement material are fiberglass.18. A structurally reinforced panel as in claim 16, wherein each of the plurality of strips has a width between about 0.15 centimeters and about 8 centimeters.19. A structurally reinforced panel as in claim 16, wherein the panel is a body panel and is selected from a quarter panel, a door panel, a roof panel, a hood panel or a trunk panel and wherein the matrix material activates at a temperature typically encountered in an e-coat or painting operation.20. A structurally reinforced panel as in claim 16, wherein the matrix material is an epoxy-based material.21. A structurally reinforced panel as in claim 16, wherein the matrix material is selected from an epoxy based material, an ethylene-based polymer or a mixture thereof.22. A structurally reinforced panel for an automotive vehicle, comprising:(a) a metal panel, the metal panel being a body panel of the automotive vehicle, the body panel being selected from a quarter panel, a door panel, a roof panel, a hood panel, a trunk panel or a floor panel; (b) a fibrous reinforcement material having a weight of less than about 20 ounces per square yard, adjoining said panel, wherein: i) the reinforcement material is comprised of a plurality of strips woven together as a sheet; ii) each of the plurality of strips is formed of several fiberglass fibers which are grouped together, but which are generally unwoven relative to each other and which extend substantially parallel to each other; and iii) each of the plurality of strips has a width between about 0.15 centimeters and about 8 centimeters; and (c) a matrix material selected from an epoxy based material, an ethylene-based polymer or a mixture thereof, for carrying said fibrous reinforcement material, said matrix material being bonded to said panel, over at least part of a surface of said panel wherein; i) the matrix material is a heat activated foamable material for assisting in integrating the fibrous reinforcement material with the matrix material; and ii) the matrix material activates at a temperature typically encountered in an e-coat or painting operation. 23. A structurally reinforced panel as in claim 22, wherein said woven roving weighs less than 15 ounces per square yard.24. A structurally reinforced panel as in claim 22, wherein said woven roving thickness about 5 mils or higher.