Reinforcement device

Reinforcement components for structural members are disclosed. The reinforcement components have expansible reinforcement material that adheres to and reinforces structural members following activation. Methods of reinforcing are disclosed. Reinforced structural members are described.

FIELD

The present disclosure relates to devices used to reinforce mechanical structures.

BACKGROUND

Mechanical structures are present in automobiles, household appliances, flooring, machine shells, washer/dryers, airplanes, boats, or various tools. Many mechanical structures contain cavities. It is desirable to reinforce portions of the structural members surrounding such cavities. Such reinforcement can provide impact energy absorption in crash situations. Such reinforcement can also mitigate vibration and resultant noise. It is desirable to absorb impact energy and/or minimize vibration using reinforcement components that add as little weight as possible to the overall mechanical structure.

It is also desirable to have reinforcement components that are easily integrated into the manufacturing process. For example, in the case of an automobile, a reinforcement component that can readily be maneuvered into a cavity during assembly is desired.

Certain structural members contain more than one cavity, which may be adjoining. For such structural members, it is desirable to have a single component that can be placed into more than one of the cavities of the structural member during assembly. This can reduce the overall number of components used for reinforcement and therefore reduce the total weight of the components used for reinforcement.

It is also desirable that reinforcement components have at least one surface with expansible material thereon. After the reinforcement component is placed into the structural member and the structural member undergoes sufficient exposure to heat (such as during a paint bake process), the expansible material expands, cures and adheres to the structural member, thereby reinforcing the structural member.

DETAILED DESCRIPTION OF THE DRAWINGS

The figures disclosed and described herein are illustrative examples of the appended claims, and are not intended to be limiting.

FIGS. 1-2provide alternative views of a reinforcement component10that can be used to reinforce structural members having more than one cavity. Such structural members are found in mechanical bodies such as automobiles, household appliances, flooring, machine shells, washer/dryers, airplanes, boats, or various tools.

The reinforcement component10has a first portion12and a second portion14. The first portion12and the second portion14can comprise any material, including metal materials and plastic materials such as nylon and/or other light weight plastic materials, and combinations thereof. First portion12and second portion14can be integrally formed by any method. By way of non-limiting examples, the integral formation can be achieved by injection molding or by extrusion. Other manufacturing processes may also be suitable. The first portion12and the second portion14may also be separately formed and later joined together or connected using any method.

FIGS. 1-2depict an expansible reinforcement material16disposed on both a surface of the first portion12and on a surface of the second portion14. Alternatively, expansible reinforcement material16may be disposed on a surface of only the first portion12or the second portion14. Any expansible reinforcement material may be used. For example, epoxy resin-based materials are suitable. Expansible materials may include thermosetting and thermoplastic polymers, rubbers such as SBS block-copolymers, tackifiers, curing agents, chemical and/or physical blowing agents, rheology agents, fillers, pigments, and other ingredients. The Sika Corporation sells thermally expansible reinforcer materials under the trade name SIKAREINFORCER that are suitable for use with the reinforcement component10. A series of these thermally expansible reinforcer materials, owned by the Sika Corporation, are described in the U.S. Pat. No. 6,387,470, incorporated herein by reference in its entirety. Other suitable expansible materials are disclosed in U.S. Published Patent Application No. 2007/0110951, incorporated herein by reference in its entirety.

Any process may be used to dispose the expansible reinforcement material16on a surface of the first portion12and on a surface of the second portion14. Such processes include but are not limited to overmolding and/or adhering or otherwise affixing strips or other shapes of the expansible material16on a surface of the first portion12and/or on a surface of the second portion14.

Optionally, an expansible baffle material15may be used with the reinforcement component10. InFIGS. 1-2, the baffle material15is depicted atop the second portion14, though it is contemplated that the baffle material15could be located anywhere on the reinforcement component10. Any known baffle material may be used that is capable of expanding and substantially sealing off a cavity to reduce the ability of noise to carry through the cavity. Such baffle materials may include epoxy resin, thermosetting and thermoplastic polymers (including but not limited to ethylene vinyl acetate), tackifiers, curing agents, chemical and/or physical blowing agents, rheology agents, fillers, pigments, and other ingredients. The Sika Corporation sells suitable thermally expansible baffling materials under the SIKABAFFLE trade name, which are described in U.S. Pat. Nos. 5,266,133 and 5,373,027, both of which are incorporated herein by reference in their entireties.

Any process may be used to dispose the baffle material15on a surface of the reinforcement component10. Such processes include but are not limited to overmolding and/or adhering or otherwise affixing strips or other shapes of baffle material15on a surface of the reinforcement component10. Such processes also include the use of mechanical fasteners such as clips, pins, bolts or other suitable fasteners.

FIG. 3depicts a B-pillar having more than one cavity. However, it is contemplated that any structural member having multiple cavities, including adjoining cavities, could be reinforced by the reinforcement component10. InFIG. 3, structural member26has a first cavity32with a first longitudinal axis and a second cavity34with a second longitudinal axis. The first and second longitudinal axes are substantially parallel. It is contemplated that longitudinal axes could be exactly parallel, substantially parallel, or in another physical arrangement. The first cavity32is defined in part by a first wall36of the first cavity32. The second cavity34is defined in part by a second wall38of the second cavity34. The first and second cavities32and34are separated by a barrier28. The barrier28has an opening30, as depicted inFIG. 6, joining the first and the second cavities32and34.

The first portion12can have any size and shape that is adapted to fit at least partially in a first cavity32of a structural member26. The second portion14can have any size and shape that is adapted to fit at least partially in a second cavity34of the structural member26. AlthoughFIGS. 1-4show only first and second portions, it is contemplated that a reinforcement component10could be designed and fabricated to include additional portions adapted to fit into additional cavities of a structural member.

InFIG. 4, the first portion12and the second portion14are cellular, having upright hollow volumes18alternating between inverted hollow volumes20. Support walls22may optionally divide hollow volumes18and20. Hollow volumes18and20are shown to be open on a first end and substantially closed on a second end opposite the first end, but other constructions are suitable. For example, the hollow volumes may be closed or substantially closed on the first end and the second end. Additionally, it is not critical to alternate between upright hollow volumes18and inverted hollow volumes20. Designs with hollow volumes all being oriented upright or all being oriented inverted are contemplated, as are other arrangements. It is also not critical that the volumes be entirely hollow. The volumes may contain various ribs, protrusions and other structural features. The inclusion of a substantially hollow structure is merely one way to form a light weight reinforcement component10.

InFIGS. 5-7, the reinforcement component10is depicted as being maneuvered through the barrier28of the structural member26. The first portion12is sized and shaped to fit through the opening30. As depicted inFIGS. 5 and 6, the first portion12can be maneuvered through the opening30to enter the first cavity32by pivoting the first portion12about an edge of the opening30of the barrier28. During maneuvering, force may be applied against the second portion14such that a prong24on the reinforcement component10passes through a bore25in the barrier28and becomes engaged with the barrier28, as depicted inFIG. 7. The use of a prong is merely exemplary and any securing fastener may be used such as screw, bolt, clamp, clip, or other mechanical brace. The mechanical engagement of the prong24to the barrier28secures the reinforcement component10within the cavities32and34of the structural member26. Depending on the shape of the reinforcement component10, the nature of the opening30, and the cavities being reinforced, the maneuvering process may invoke a number of different motions including gyratory, rotary, and revolving, as well as sliding, pushing, twisting, and jostling.

After maneuvering and upon securing of the reinforcement component10, the first portion12occupies at least a portion of the first cavity32. The second portion14occupies at least a portion of the second cavity34. The first portion12and the second portion14are connected at a region that fits through the opening. The opening30is substantially closed when the reinforcement component10is secured in the barrier28. Thus, when the reinforcement component10is secured, first cavity32and second cavity34are substantially or entirely separated, as shown inFIG. 3.

Methods of Reinforcing Structural Members

The reinforcement component10can be used to reinforce structural members found in mechanical bodies. By way of non-limiting example, when an automobile is being assembled, a reinforcement component10can be positioned into a cavity of a structural member such as an A-pillar, a B-pillar, a front rail, a rear rail, a rocker, a roof rail, or any structural member having at least two cavities.

After the reinforcement component10is placed into a structural member26of an automobile, the automobile is exposed to heat, such as during the paint-bake process. The heat causes the expansible reinforcement material16to undergo internal cross linking and to expand, cure and adhere to at least one of a plurality of walls surrounding the cavity in the structural member.

The expansible reinforcement material16expands to at least about 50% beyond an initial thickness. The expansible reinforcement material may expand to at least about 75%, at least about 100%, at least about 150%, or at least about 200%.

The expanded expansible reinforcement material may have a compressive strength of at least about 1000 psi, at least about 1200 psi, or at least about 1400 psi. The expanded expansible reinforcement material is adhered to both (1) a surface of the first or second portions of upon which the expansible reinforcement material was initially disposed, and (2) at least one wall defining a cavity of the structural member26. Thus, the expanded expansible reinforcement material16joins the reinforcement component10with the structural member26and reinforces the structural member26. The areas of the structural member26at or near the reinforcement component10are reinforced. As such the reinforced areas can be less susceptible to undesirable noise and vibration, and/or can absorb a greater amount of kinetic energy during a crash situation. The extent of the reinforcement depends at least in part on the compressive strength of the expanded expansible reinforcement material.

In embodiments where reinforcement component10also includes a baffle material, the baffle material would also expand during exposure to heat such as in a paint bake process to substantially seal off a cavity to prevent undesirable noise from traveling through the cavity. The baffle material may also adhere to the walls of the cavity. The baffle material may expand at least about 100% beyond an initially applied thickness. The baffle material may also expand at least about 260%, at least about 500%, at least about 1500%, or at least about 2000%.

The appended claims have been particularly shown and described with reference to the foregoing embodiments, which are merely illustrative of the best modes for carrying out the invention defined by the appended claims. It should be understood by those skilled in the art that various alternatives to the embodiments described herein may be employed in practicing the invention defined by the appended claims without departing from the spirit and scope of the invention as defined in claims. The embodiments should be understood to include all novel and non-obvious combinations of elements described herein, and claims may be presented in this or a later application to any novel and non-obvious combination of these elements. Moreover, the foregoing embodiments are illustrative, and no single feature or element is essential to all possible combinations that may be claimed in this or a later application.