CA2617919A1 - Reinforcements, baffles and seals with malleable carriers - Google Patents

Reinforcements, baffles and seals with malleable carriers Download PDF

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Publication number
CA2617919A1
CA2617919A1 CA002617919A CA2617919A CA2617919A1 CA 2617919 A1 CA2617919 A1 CA 2617919A1 CA 002617919 A CA002617919 A CA 002617919A CA 2617919 A CA2617919 A CA 2617919A CA 2617919 A1 CA2617919 A1 CA 2617919A1
Authority
CA
Canada
Prior art keywords
carrier
malleable
malleable carrier
activatable material
shaping
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA002617919A
Other languages
French (fr)
Other versions
CA2617919C (en
Inventor
Todd Gray
Thomas L. Coon
Matthew Thomas
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Zephyros Inc
Original Assignee
Zephyros, Inc.
Todd Gray
Thomas L. Coon
Matthew Thomas
L & L Products Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Zephyros, Inc., Todd Gray, Thomas L. Coon, Matthew Thomas, L & L Products Inc. filed Critical Zephyros, Inc.
Publication of CA2617919A1 publication Critical patent/CA2617919A1/en
Application granted granted Critical
Publication of CA2617919C publication Critical patent/CA2617919C/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/88—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/18—Filling preformed cavities
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/688—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks the inserts being meshes or lattices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/72—Encapsulating inserts having non-encapsulated projections, e.g. extremities or terminal portions of electrical components
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/001—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material
    • B62D29/002—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material a foamable synthetic material or metal being added in situ
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
    • H01L2924/0001—Technical content checked by a classifier
    • H01L2924/0002—Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49616—Structural member making
    • Y10T29/49622—Vehicular structural member making
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/4998—Combined manufacture including applying or shaping of fluent material

Abstract

There is disclosed a process of forming reinforcements, baffles and seals having malleable carriers (10). The process typically includes application of an activatable material (38) to a malleable carrier (10) and contouring of the activatable material (38) the malleable carrier (10) or both.

Claims (18)

1. A process of forming and/or applying a member for reinforcing a structure of an automotive vehicle, the process comprising:
providing a malleable carrier formed of a material that has a yield stress greater than 100 MPa and less than 1000 MPa;
associating an activatable material with the malleable carrier thereby forming the member wherein the volume of activatable material is at least 500%

of the volume of the malleable carrier;
shaping the malleable carrier, the activatable material or both wherein the shaping step and the associating step include at least one of the following:
i. shaping the malleable carrier to a predetermined configuration that corresponds to a cavity of a vehicle and molding the activatable material onto the malleable carrier;
or ii. molding the activatable material upon the malleable carrier for forming the member and applying the member to a structure in a manner that includes shaping the malleable carrier and the activatable material prior to or during location of the member in a cavity of a vehicle; and expanding the activatable material to form a structural foam that assists in reinforcing a portion of the vehicle;
wherein associating the activatable material with the malleable carrier includes substantially surrounding the malleable carrier with the activatable material.
2. A process as in claim 1 wherein the malleable carrier has a yield stress less than about 700 MPa and greater than about 100 MPa.
3. A process as in claim 1 or 2 wherein the activatable material is generally dry and substantially non-tacky.
4. A process as in claim 1, 2 or 3 wherein the malleable carrier is formed of metal.
5. A process as in claim 1, 2, 3 or 4 wherein the malleable carrier is formed of one or more strips.
6. A process as in claim 1, 2, 3, 4 or 5 wherein the malleable carrier has a yield stress less than about 500 MPa and greater than about 250 MPa.
7. A process as in any of claims 1-6 wherein the malleable carrier is formed of a plurality of strips intertwined with each other.
8. A process as in any of claims 1-7 wherein the malleable carrier is formed of a wire mesh.
9. A process as in any of claims 1-6 wherein the malleable carrier is formed of a single strip.
10. A process as in any of claims 1-5 wherein:
i. the malleable carrier has a frame portion and a first tab and a second tab, the first tab in a hook shape;
ii. shaping of the malleable carrier includes hooking the first tab about a first edge of a structure and bending the second tab about a second edge of the structure.
11. A process as in any of claims 1-6 wherein the shaping step includes attaching the member to a secondary carrier wherein attaching of the member includes shaping of the member including the malleable carrier and the activatable material to accommodate one or more contours of the secondary carrier.
12. A process as in claim 11 wherein shaping includes bending or curving of the member.
13. A process as in claim 11 or 12 wherein the malleable carrier is in the form of a singular elongated strip having a plurality of through-holes.
14. A process as in claim 11, 12 or 13 wherein the malleable carrier includes a plurality of widened portion with one of the plurality of through-holes through each of the widened portions.
15. A process as in claim 13 or 14 further comprising:
extending a plurality of fasteners through the plurality of through-holes wherein the attaching of the member includes attaching the fasteners to the structure or secondary carrier.
16. A process as in claim 15 wherein the activatable material is molded about at least a portion of the plurality of fasteners,
17. A method as in any of claims 1-16 wherein the activatable material is a heat activated thermosetting material that foams, expands and cure upon exposure to temperature in an e-coat or bake oven.
18
CA2617919A 2005-08-04 2006-08-02 Reinforcements, baffles and seals with malleable carriers Expired - Fee Related CA2617919C (en)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
US70556105P 2005-08-04 2005-08-04
US60/705,561 2005-08-04
US11/461,557 US7926179B2 (en) 2005-08-04 2006-08-01 Reinforcements, baffles and seals with malleable carriers
US11/461,557 2006-08-01
PCT/US2006/030480 WO2007019330A1 (en) 2005-08-04 2006-08-02 Reinforcements, baffles and seals with malleable carriers

Publications (2)

Publication Number Publication Date
CA2617919A1 true CA2617919A1 (en) 2007-02-15
CA2617919C CA2617919C (en) 2012-10-16

Family

ID=37453105

Family Applications (1)

Application Number Title Priority Date Filing Date
CA2617919A Expired - Fee Related CA2617919C (en) 2005-08-04 2006-08-02 Reinforcements, baffles and seals with malleable carriers

Country Status (7)

Country Link
US (3) US7926179B2 (en)
EP (1) EP1910052A1 (en)
JP (1) JP5236471B2 (en)
KR (1) KR101359240B1 (en)
CN (1) CN101356051B (en)
CA (1) CA2617919C (en)
WO (1) WO2007019330A1 (en)

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US20120060352A1 (en) 2012-03-15
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US20100257738A1 (en) 2010-10-14
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US7926179B2 (en) 2011-04-19
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US20070045866A1 (en) 2007-03-01
US8079146B2 (en) 2011-12-20

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