WO2003093064A1 - Vehicle body cavity filler - Google Patents

Vehicle body cavity filler Download PDF

Info

Publication number
WO2003093064A1
WO2003093064A1 PCT/US2003/013478 US0313478W WO03093064A1 WO 2003093064 A1 WO2003093064 A1 WO 2003093064A1 US 0313478 W US0313478 W US 0313478W WO 03093064 A1 WO03093064 A1 WO 03093064A1
Authority
WO
WIPO (PCT)
Prior art keywords
foamable material
mass
cavity
vertical walls
vehicle body
Prior art date
Application number
PCT/US2003/013478
Other languages
French (fr)
Inventor
Matthew J. Blain
Kousay M. Said
Shailesh S. Bhat
Original Assignee
Dow Global Technologies, 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 Dow Global Technologies, Inc. filed Critical Dow Global Technologies, Inc.
Priority to AU2003232021A priority Critical patent/AU2003232021A1/en
Publication of WO2003093064A1 publication Critical patent/WO2003093064A1/en

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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
    • 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
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/08—Insulating elements, e.g. for sound insulation

Definitions

  • the instant invention is in the field of vehicle construction. More specifically, the instant invention relates to a means for filling or blocking the cavity of an automotive body pillar or similar member.
  • the body of a light truck, sedan, station wagon, mini-van, sport utility vehicle or the like is generally made by welding together stamped sheet metal sections.
  • Such a body comprises a number of tubular hollow spaces or cavities defined by, for example, the pillars or channels that surround the passenger compartment of the vehicle.
  • the instant invention provides a solution to the above-mentioned problems. More specifically, the instant invention is a process for filling a cavity of a vehicle body, the cavity defined by vertical walls, characterized by the steps of: (a) attaching a mass of a foamable material to one of the vertical walls, the foamable material capable of expanding when heated; (b) heating the foamable material so that the foamable material expands to bridge the vertical walls of the cavity.
  • An important benefit of the instant invention is that the mass of foamable material can be applied by hand.
  • Another important benefit of the instant invention is that the mass of foamable material can be easily and inexpensively shaped because no complex part tooling is required. Fig.
  • FIG. 1 (a) and (b) show a cross-sectional side view of a process embodiment of the instant invention wherein a mass of a foamable material is attached to a vertical sheet steel wall of a vehicle body cavity by way of a magnet and then heated to foam the foamable material to bridge the cavity;
  • FIG. 2 (a) and (b) show a cross-sectional side view of another process embodiment of the instant invention wherein a mass of a foamable material is attached to a vertical wall of a vehicle body cavity by way of a tacky surface on the foamable material and then heated to foam the foamable material to bridge the cavity;
  • Fig. 3 (a) and (b) show a cross-sectional side view of another process embodiment of the instant invention wherein a mass of a foamable material is attached to a vertical wall of a vehicle body cavity by way of adhesive tape and then heated to foam the foamable material to bridge the cavity;
  • Fig. 4 (a) and (b) show a cross-sectional side view of yet another process embodiment of the instant invention wherein a mass of a foamable material is attached to a vertical wall of a vehicle body cavity by way of a clip and then heated to foam the foamable material to bridge the cavity.
  • the instant invention is a process for filling a cavity of a vehicle body, the cavity defined by vertical walls, comprising the steps of: (a) attaching a mass of a foamable material to one of the vertical walls, the foamable material capable of expanding when heated; (b) heating the foamable material so that the foamable material expands to bridge the vertical walls of the cavity.
  • vertical walls means that the walls are between 45 and 135 degrees of angle from the horizontal plane of the normal orientation of the vehicle body.
  • the mass of a foamable material is attached to one of the vertical walls in the stamping plant or body shop before the body parts are welded together to form the cavity.
  • a vehicle body cavity 12 is defined by sheet steel panels 10 and 11.
  • a mass of a foamable material 13 is attached to the panel 10 by way of a magnet 14.
  • Fig. 1(b) when the mass of a foamable material 13 is heated by, for example, passage of the vehicle body through an e-coat, powder coat or paint cure oven, then the mass of a foamable material 13 expands to form a foamed material 15 that bridges the panel 10 and the panel 11.
  • a vehicle body cavity 16 is defined by sheet steel panels 17 and 18.
  • a mass of a foamable material 19 is attached to the panel 10 by way of a tacky surface on the foamable material 19.
  • Fig. 2(b) when the mass of a foamable material 19 is heated by, for example, passage of the vehicle body through an e- coat, powder coat or paint cure oven, then the mass of foamable material 19 expands to form a foamed material 20 that bridges the panel 17 and the panel 18.
  • Fig. 3(a) a yet another specific embodiment of the instant invention will be disclosed.
  • a vehicle body cavity 21 is defined by sheet steel panels 22 and 23.
  • a mass of a foamable material 24 is attached to the panel 22 by way of adhesive tape 25. If the mass of a foamable material 24 is not inherently tacky so that it sticks to the adhesive tape 25, then double-sided adhesive tape can be used for the adhesive tape 25. Referring now to Fig. 3(b), when the mass of a foamable material 24 is heated by, for example, passage of the vehicle body through a paint cure oven, then the mass of foamable material 24 expands to form a foamed material 26 that bridges the panel 22 and the panel 23.
  • a vehicle body cavity 27 is defined by sheet steel panels 28 and 29.
  • a mass of a foamable material 30 is attached to the panel 28 by way of a clip 31 inserted through aperture 32 in the panel 28.
  • the clip 31 can be made of any suitable material, such as plastic or steel, but steel is a preferred material.
  • Fig. 4(b) when the mass of a foamable material 30 is heated by, for example, passage of the vehicle body through a paint cure oven, then the mass of foamable material 30 expands to form a foamed material 33 that bridges the panel 28 and the panel 29.
  • the properties of the foamable material used in the instant invention are important. For example, referring again to Fig. 2(a) and (b), as the mass of foamable material 19 expands to form the foamed material 20, it must not slip off or run down the panel 17 so that it fails to bridge the panel 17 and the panel 18.
  • Thermoset polymers including vulcanizing rubbers, polyisobutylenes and thermoplastic vulcanizates
  • foaming agents can be used in the foamable material of the instant invention as long as the above-mentioned properties are obtained.
  • the foamable material of the instant invention can comprise a thermoplastic elastomer such as an ethylene-propylene-diene terpolymer thermoplastic elastomer.
  • Thermoplastic polymers containing foaming agents can also be used in the foamable material of the instant invention as long as the above-mentioned properties are obtained.
  • the foamable material of the instant invention can comprise a thermoplastic polymer such as ethylene-vinyl-acetate polymer. Additional teachings regarding suitable foamable materials are readily available in the art, see, for example, the teachings of United States Patent 5,496,868.
  • the expanded foamable material can contribute increased structural strength to the body. For example, filling the pillars and rails of a body with such an expanded foamable material of the instant invention can significantly increase the stiffness and strength of the body as well as reduce road noise. However, if the density of the expanded foamable material is less than one tenth of a gram per cubic centimeter, then the expanded foamable material is, of course, still effective as a sound deadener but generally less effective as a structural reinforcement.
  • the foamable material of the instant invention is inherently tacky so that a mass of the foamable material can be attached to an interior surface of the cavity and remain in place (even if such surface is oily) until the vehicle body is passed through an e-coat, powder coat or paint cure oven. If the foamable material is not inherently tacky, then a tackifier can be added to the foamable material to provide this function.
  • An important benefit of the instant invention is that the mass of foamable material can be applied by hand.
  • Another important benefit of the instant invention is that the mass of foamable material can be easily and inexpensively shaped because no complex part tooling is required to form the mass of foamable material.
  • One side of an "A" pillar automotive body stamping is removed from the stamping die.
  • a mass of ND-300 thermoplastic elastomer based (ethylene-vinyl-acetate polymer based) foamable material (an inherently tacky foamable material available from ND Industries, 1000 North Crooks Road, Clawson, Michigan) is attached to the inside surface of the "A" pillar in the manner shown in Fig. 2(a).
  • the other side of the "A" pillar automotive body stamping is removed from its stamping die and spot welded to the first side to complete an automotive vehicle body.
  • the automotive vehicle body is passed through an e- coat oven, which heats the foamable material in the "A" pillar cavity so that the foamable material expands to bridge the vertical walls of the "A" pillar in the manner shown in Fig. 2(b).

Abstract

A process for filling a cavity (16) of a vehicle body, the cavity defined by vertical walls (17) (18) such as the 'A' pillar of an automobile body. The process includes two steps. The first step is to attach a mass of a foamable material (19) to one of the vertical walls (17), the foamable material capable of foaming when heated. The second step is to heat the foamable material so that the foamable material expands (20) to bridge the vertical walls (17) (18) of the cavity.

Description

VEHICLE BODY CAVITY FILLER
The instant invention is in the field of vehicle construction. More specifically, the instant invention relates to a means for filling or blocking the cavity of an automotive body pillar or similar member.
The body of a light truck, sedan, station wagon, mini-van, sport utility vehicle or the like is generally made by welding together stamped sheet metal sections. Such a body comprises a number of tubular hollow spaces or cavities defined by, for example, the pillars or channels that surround the passenger compartment of the vehicle. As disclosed, for example, in United States Patents 4,874,650; 4,898,630;
5,266,133; 5,373,027; 5,506,025; 5,725,272; 6,062,624; 6,146,565; and 6,150,428; if such hollow spaces or cavities are filled or blocked with, for example, a foamed polymer section or a baffle of some kind, then the noise level in the passenger compartment can be significantly reduced. For example, the above referenced United States Patents 6,146,565 and 6,150,428 disclose baffles that incorporate foaming material.
The technology disclosed, for example, in the above referenced United States Patents 4,874,650; 4,898,630; 5,266,133; 5,373,027; 5,506,025; 5,725,272; 6,062,624; 6,146,565; and 6,150,428 was an important advance in the art. However, it would be a further advance in the art if a less complex foaming filler system were discovered that did not require complicated attachment systems or complex part tooling.
The instant invention provides a solution to the above-mentioned problems. More specifically, the instant invention is a process for filling a cavity of a vehicle body, the cavity defined by vertical walls, characterized by the steps of: (a) attaching a mass of a foamable material to one of the vertical walls, the foamable material capable of expanding when heated; (b) heating the foamable material so that the foamable material expands to bridge the vertical walls of the cavity. An important benefit of the instant invention is that the mass of foamable material can be applied by hand. Another important benefit of the instant invention is that the mass of foamable material can be easily and inexpensively shaped because no complex part tooling is required. Fig. 1 (a) and (b) show a cross-sectional side view of a process embodiment of the instant invention wherein a mass of a foamable material is attached to a vertical sheet steel wall of a vehicle body cavity by way of a magnet and then heated to foam the foamable material to bridge the cavity; Fig. 2 (a) and (b) show a cross-sectional side view of another process embodiment of the instant invention wherein a mass of a foamable material is attached to a vertical wall of a vehicle body cavity by way of a tacky surface on the foamable material and then heated to foam the foamable material to bridge the cavity;
Fig. 3 (a) and (b) show a cross-sectional side view of another process embodiment of the instant invention wherein a mass of a foamable material is attached to a vertical wall of a vehicle body cavity by way of adhesive tape and then heated to foam the foamable material to bridge the cavity; and
Fig. 4 (a) and (b) show a cross-sectional side view of yet another process embodiment of the instant invention wherein a mass of a foamable material is attached to a vertical wall of a vehicle body cavity by way of a clip and then heated to foam the foamable material to bridge the cavity.
The instant invention is a process for filling a cavity of a vehicle body, the cavity defined by vertical walls, comprising the steps of: (a) attaching a mass of a foamable material to one of the vertical walls, the foamable material capable of expanding when heated; (b) heating the foamable material so that the foamable material expands to bridge the vertical walls of the cavity. The term "vertical walls" means that the walls are between 45 and 135 degrees of angle from the horizontal plane of the normal orientation of the vehicle body. Ordinarily, the mass of a foamable material is attached to one of the vertical walls in the stamping plant or body shop before the body parts are welded together to form the cavity.
Referring now to Fig. 1(a), a more specific embodiment of the instant invention will be disclosed. A vehicle body cavity 12 is defined by sheet steel panels 10 and 11. A mass of a foamable material 13 is attached to the panel 10 by way of a magnet 14. Referring now to Fig. 1(b), when the mass of a foamable material 13 is heated by, for example, passage of the vehicle body through an e-coat, powder coat or paint cure oven, then the mass of a foamable material 13 expands to form a foamed material 15 that bridges the panel 10 and the panel 11.
Referring now to Fig. 2(a), another specific embodiment of the instant invention will be disclosed. A vehicle body cavity 16 is defined by sheet steel panels 17 and 18. A mass of a foamable material 19 is attached to the panel 10 by way of a tacky surface on the foamable material 19. Referring now to Fig. 2(b), when the mass of a foamable material 19 is heated by, for example, passage of the vehicle body through an e- coat, powder coat or paint cure oven, then the mass of foamable material 19 expands to form a foamed material 20 that bridges the panel 17 and the panel 18. Referring now to Fig. 3(a), a yet another specific embodiment of the instant invention will be disclosed. A vehicle body cavity 21 is defined by sheet steel panels 22 and 23. A mass of a foamable material 24 is attached to the panel 22 by way of adhesive tape 25. If the mass of a foamable material 24 is not inherently tacky so that it sticks to the adhesive tape 25, then double-sided adhesive tape can be used for the adhesive tape 25. Referring now to Fig. 3(b), when the mass of a foamable material 24 is heated by, for example, passage of the vehicle body through a paint cure oven, then the mass of foamable material 24 expands to form a foamed material 26 that bridges the panel 22 and the panel 23.
Referring now to Fig. 4(a), yet another specific embodiment of the instant invention will be disclosed. A vehicle body cavity 27 is defined by sheet steel panels 28 and 29. A mass of a foamable material 30 is attached to the panel 28 by way of a clip 31 inserted through aperture 32 in the panel 28. The clip 31 can be made of any suitable material, such as plastic or steel, but steel is a preferred material. Referring now to Fig. 4(b), when the mass of a foamable material 30 is heated by, for example, passage of the vehicle body through a paint cure oven, then the mass of foamable material 30 expands to form a foamed material 33 that bridges the panel 28 and the panel 29.
The properties of the foamable material used in the instant invention are important. For example, referring again to Fig. 2(a) and (b), as the mass of foamable material 19 expands to form the foamed material 20, it must not slip off or run down the panel 17 so that it fails to bridge the panel 17 and the panel 18. Thermoset polymers (including vulcanizing rubbers, polyisobutylenes and thermoplastic vulcanizates) containing foaming agents can be used in the foamable material of the instant invention as long as the above-mentioned properties are obtained. For example, the foamable material of the instant invention can comprise a thermoplastic elastomer such as an ethylene-propylene-diene terpolymer thermoplastic elastomer. Thermoplastic polymers containing foaming agents can also be used in the foamable material of the instant invention as long as the above-mentioned properties are obtained. For example, the foamable material of the instant invention can comprise a thermoplastic polymer such as ethylene-vinyl-acetate polymer. Additional teachings regarding suitable foamable materials are readily available in the art, see, for example, the teachings of United States Patent 5,496,868.
If the density of the expanded foamable material is greater than one tenth of a gram per cubic centimeter, then the expanded foamable material can contribute increased structural strength to the body. For example, filling the pillars and rails of a body with such an expanded foamable material of the instant invention can significantly increase the stiffness and strength of the body as well as reduce road noise. However, if the density of the expanded foamable material is less than one tenth of a gram per cubic centimeter, then the expanded foamable material is, of course, still effective as a sound deadener but generally less effective as a structural reinforcement. Preferably, the foamable material of the instant invention is inherently tacky so that a mass of the foamable material can be attached to an interior surface of the cavity and remain in place (even if such surface is oily) until the vehicle body is passed through an e-coat, powder coat or paint cure oven. If the foamable material is not inherently tacky, then a tackifier can be added to the foamable material to provide this function. An important benefit of the instant invention is that the mass of foamable material can be applied by hand. Another important benefit of the instant invention is that the mass of foamable material can be easily and inexpensively shaped because no complex part tooling is required to form the mass of foamable material.
It should be understood that many other embodiments of the instant invention can be readily attained in addition to the above described specific embodiments. EXAMPLE
One side of an "A" pillar automotive body stamping is removed from the stamping die. A mass of ND-300 thermoplastic elastomer based (ethylene-vinyl-acetate polymer based) foamable material (an inherently tacky foamable material available from ND Industries, 1000 North Crooks Road, Clawson, Michigan) is attached to the inside surface of the "A" pillar in the manner shown in Fig. 2(a). The other side of the "A" pillar automotive body stamping is removed from its stamping die and spot welded to the first side to complete an automotive vehicle body. The automotive vehicle body is passed through an e- coat oven, which heats the foamable material in the "A" pillar cavity so that the foamable material expands to bridge the vertical walls of the "A" pillar in the manner shown in Fig. 2(b).

Claims

WHAT IS CLAIMED IS:
1. A process for filling a cavity (16) of a vehicle body, the cavity defined by vertical walls (17) (18), characterized by the steps of: (a) attaching a mass of a foamable material (19) to one of the vertical walls (17), the foamable material capable of foaming when heated; (b) heating the foamable material so that the foamable material expands (20) to bridge the vertical walls (17) (18) of the cavity.
2. The process of Claim 1, wherein in step (a), the vertical walls comprise sheet steel (10) (11) and the mass of foamable material (13) is attached to the sheet steel by way of a magnet (14).
3. The process of Claim 1, wherein in step (a), the mass of foamable material (19) is attached to one of the vertical walls (17) (18) of the cavity (16) by way of a tacky surface on the mass of foamable material (19).
4. The process of Claim 1, wherein in step (a), the mass of foamable material (30) is attached to one of the vertical walls (28) of the cavity (27) by way of a clip (31) attached to the mass of foamable material (30).
5. The process of Claim 1, wherein the foamed material (20) of step (b) has a density of less than one tenth of a gram per cubic centimeter.
6. The process of Claim 1, wherein the foamed material (20) of step (b) has a density of more than one tenth of a gram per cubic centimeter.
7. The process of Claim 3, wherein the tacky surface on the foamable material (24) is provided by adhesive tape (25) attached to the surface of the mass of foamable material (24).
8. The process of Claim 1, wherein the foamable material (19) comprises an unvulcanized rubber, a vulcanizing agent and a foaming agent.
9. The process of Claim 1, wherein the foamable material (19) comprises a thermoplastic resin and a foaming agent.
10. The process of Claim 9, wherein the thermoplastic resin comprises an ethylene-vinyl-acetate polymer.
PCT/US2003/013478 2002-05-02 2003-05-01 Vehicle body cavity filler WO2003093064A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
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US37738702P 2002-05-02 2002-05-02
US60/377,387 2002-05-02

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7784186B2 (en) 2003-06-26 2010-08-31 Zephyros, Inc. Method of forming a fastenable member for sealing, baffling or reinforcing
US7950723B2 (en) 2005-06-07 2011-05-31 Zephyros, Inc. Noise reduction member and system
WO2013177377A1 (en) * 2012-05-24 2013-11-28 Zephyros, Inc. Vehicle body structure cut zones
US20180297253A1 (en) * 2015-10-13 2018-10-18 Tesa Se Method for joining two components of different materials
EP3763571A1 (en) * 2019-07-11 2021-01-13 Treves Products, Services & Innovation Acoustic shield for a motor vehicle engine

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US5725272A (en) 1996-06-27 1998-03-10 Sika Corporation Drain assembly for acoustic baffle system
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US6146565A (en) 1998-07-15 2000-11-14 Noble Polymers, L.L.C. Method of forming a heat expandable acoustic baffle
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US4898630A (en) 1987-11-18 1990-02-06 Toyota Jidosha Kabushiki Thermosetting highly foaming sealer and method of using it
US4874650A (en) 1987-12-21 1989-10-17 Toyota Jidosha Kabushiki Kaisha Thermosetting foaming sealer
US4810548A (en) * 1988-08-01 1989-03-07 Ligon Brothers Manufacturing Company Sandwich seal fixture
WO1993005103A1 (en) * 1991-09-03 1993-03-18 Terence Allan Russell Strengthening structures
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US5373027A (en) 1993-02-17 1994-12-13 Sika Corporation Dry expansible sealant and baffle composition and product
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US5496868A (en) 1993-05-21 1996-03-05 Bridgestone Corporation Sealing material and method
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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7784186B2 (en) 2003-06-26 2010-08-31 Zephyros, Inc. Method of forming a fastenable member for sealing, baffling or reinforcing
US7950723B2 (en) 2005-06-07 2011-05-31 Zephyros, Inc. Noise reduction member and system
WO2013177377A1 (en) * 2012-05-24 2013-11-28 Zephyros, Inc. Vehicle body structure cut zones
US8926005B2 (en) 2012-05-24 2015-01-06 Zephyros, Inc. Vehicle body structure cut zones
US20180297253A1 (en) * 2015-10-13 2018-10-18 Tesa Se Method for joining two components of different materials
EP3763571A1 (en) * 2019-07-11 2021-01-13 Treves Products, Services & Innovation Acoustic shield for a motor vehicle engine
FR3098630A1 (en) * 2019-07-11 2021-01-15 Treves Products, Services & Innovation Acoustic protection screen for motor vehicle engine

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