[미국특허]
Method of making composite laminate automotive structures
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B21D-047/00
B23P-017/00
출원번호
US-0170064
(2002-06-12)
발명자
/ 주소
Wycech, Joseph S.
출원인 / 주소
Henkel Kommanditgesellschaft auf Aktien
인용정보
피인용 횟수 :
16인용 특허 :
27
초록▼
A structural member having at least two non-coplanar surfaces is reinforced by providing a drop in insert between the surfaces. The insert is a carrier having an expandable structural foam intimately bonded to the carrier. When the foam is expanded, the foam becomes intimately bonded to the surfaces
A structural member having at least two non-coplanar surfaces is reinforced by providing a drop in insert between the surfaces. The insert is a carrier having an expandable structural foam intimately bonded to the carrier. When the foam is expanded, the foam becomes intimately bonded to the surfaces of the structural member to reinforce the structural member.
대표청구항▼
1. A method of reinforcing a structural member having at least two non-coplanar surfaces comprising providing a drop in insert in the form of a carrier having an expandable structural foam intimately bonded to the carrier, disposing the insert at the structural member, activating the foam to expand
1. A method of reinforcing a structural member having at least two non-coplanar surfaces comprising providing a drop in insert in the form of a carrier having an expandable structural foam intimately bonded to the carrier, disposing the insert at the structural member, activating the foam to expand the foam into contact with at least two of the non-coplanar surfaces of the structural member, and intimately bonding the expanded foam to the at least two non-coplanar surfaces of the structural member to thereby reinforce the structural member.2. The method of claim 1 wherein the expandable structural foam is heat expandable and is activated by the application of heat.3. The method of claim 2 wherein the structural member is a vehicle component and the method is carried out as part of a vehicle assembly line.4. The method of claim 3 wherein the heat activation takes place in a downstream paint oven.5. The method of claim 4 wherein the vehicle component is selected from the group consisting of a radiator support beam, a door beam, a bumper, a rocker, a pillar, a C-rail section, a drive shaft and a side impact beam.6. The method of claim 1 wherein the structural member is a vehicle component and the method is carried out as part of a vehicle assembly line.7. The method of claim 6 wherein the vehicle component is selected from the group consisting of a radiator support beam, a door beam, a bumper, a rocker, a pillar, a C-rail section, a drive shaft and a side impact beam.8. The method of claim 1 wherein the structural member is of generally channel shape having a pair of side walls interconnected by a base wall.9. The method of claim 8 wherein the carrier is generally U-shaped having an outer surface and the structural foam is intimately bonded to the outer surface of the carrier.10. The method of claim 9 wherein after activation the structural foam is intimately bonded to the side walls and base wall of the structural member.11. The method of claim 8 wherein a cap is mounted over the channel opposite and remote from the base wall, the carrier being of tube shaped form, intimately bonding the expandable structural foam around the periphery of the carrier, and upon activation intimately bonding the structural foam to the side walls and interconnecting wall of the channel and to the cap covering the channel.12. The method of claim 8 wherein the carrier is of a shape which conforms to the shape of the channel thereby having side walls interconnected by a base wall.13. The method of claim 12 wherein the carrier is a hollow tube.14. The method of claim 13 wherein the carrier is disposed near the inner surfaces of the channel walls, the structural foam being in the form of a thin ribbon around and intimately bonded to the outer surface of the carrier, and the structural foam filling the space between the carrier and the structural member upon expansion of the foam.15. The method of claim 14 wherein the structural foam is a plastic resin having a thickness in the range of 1.52 mm-12.7 mm before expansion.16. The method of claim 15 wherein the resin includes hollow microspheres.17. The method of claim 1 wherein the structural member is made of metal, and the structural foam being in the form of a resin based layer intimately bonded to the carrier.18. The method of claim 17 wherein the metal is a high strength steel having a thickness of 0.050 inches-0.080 inches and the structural foam is a resin based layer having a thickness of 0.06-0.25 inches before expansion.19. A method of increasing the stiffness-to-mass ratio of a part having an inner wall which defines a cavity, comprising the steps of:forming an inner member which fits within the cavity defined by said part; placing a layer or ribbon of an expandable resin having a thickness of from 1.52 mm to 12.7 mm on either at least a portion of the outer surface of the inner member or on the inner wall of the part; inserting the inner member in said cavity to form an assembly such that said resin is in contact with the outer surface of the inner member and the inner wall of the part, and activating the resin whereby the resin expands bonding the part to the inner member; such that the stiffness of said part is increased non-linearly over the increase in mass created by the addition of the inner member and the resin to the part. 20. A method of making a laminate beam comprising the steps of:providing an outer structural portion; forming an inner tube portion open along at least one side for substantially its entire length and having an outer wall surface and an inner wall surface, the inner wall surface of the inner tube portion defining a first cavity, which inner tube portion fits within a second cavity defined by the outer structural portion; placing a layer or ribbon of a thermoset and/or expandable resin on at least a portion of the outer wall surface of the inner tube portion, the resin comprising an epoxy resin and a curing agent and a blowing agent and glass microspheres; inserting the inner tube portion in the second cavity to form an assembly in which at least a portion of the outer wall surface of the inner tube portion closely conforms to the inner wall surface of outer structural portion and heating the assembly to a temperature whereby the resin is cured and/or expands in place to form a resin placed material layer in the region of close conformity and to bond the outer structural portion to the inner tube portion. 21. A method of making a laminate beam comprising the steps of:providing an outer structural portion; forming an inner tube portion open along at least one side for substantially its entire length and having an outer wall surface and an inner wall surface, the inner wall surface of the inner tube portion defining a first cavity, which inner tube portion fits within a second cavity defined by the outer structural portion; placing a layer or ribbon of a thermoset and/or expandable resin on at least a portion of the outer wall surface of the inner tube portion; inserting the inner tube portion in the second cavity to form an assembly in which at least a portion of the outer wall surface of the inner tube portion closely conforms to the inner wall surface of outer structural portion and heating the assembly to a temperature whereby the resin is cured and/or expands in place to form a resin placed material layer having a thickness of from 0.060 to 0.50 inch in the region of close conformity and to bond the outer structural portion to the inner tube portion. 22. The method of claim 21 wherein the outer structural portion and said inner tube portion have substantially the same shape.23. The method of claim 21 wherein the resin-based material layer is structural foam.24. The method of claim 23 wherein the structural foam is a cured thermoset resin.25. The method of claim 23 wherein the structural foam is a expanded expandable resin.26. The method of claim 21 for manufacturing a vehicle component and the method is carried out as part of a vehicle assembly line.27. A method of claim 26 wherein the vehicle component is selected from the group consisting of a radiator support beam, a door beam, a bumper, a rocker, a pillar, a C-rail section, a drive shaft and a side impact beam.28. The method of claim 21 wherein the outer structural portion and the inner tube portion are metal.29. The method of claim 21 wherein the inner tube portion is of roll-formed metal.30. The method of claim 21 wherein said resin-based material layer has a density of from 15-40 pounds per cubic foot.
Yates Derek N. (Los Gatos CA) Presta John C. (San Jose CA), Fiber reinforced composite shaft with metallic connector sleeves mounted by connector ring interlock.
Hutton Roger L. (3141 Pikewood Ct. Milford MI 48042) Williams ; Jr. John P. (10475 Moon Lake Ct. Pinckney MI 48169), Induction tacking method and apparatus.
Muenz, Xaver; Mayer, Bernd; Scheffner, Christian; Agarwal, Rajat K.; Puckett, Michael S.; Ferguson, Gregory A.; Lammerschop, Olaf, Foamable compositions based on epoxy resins and polyesters.
Wycech, Joseph S., Method for forming a tangible item and a tangible item which is made by a method which allows the created tangible item to efficiently absorb energy.
Kipp, Michael D.; Pugh, Dilworth L.; Ridges, Michael D.; McCarvill, William T., Utility materials incorporating a microparticle matrix formed with a setting agent.
※ AI-Helper는 부적절한 답변을 할 수 있습니다.