STRUCTURAL REINFORCEMENT MEMBER FOR WHEEL WELL

Abstract: A structural reinforcement member (10) for reinforcing a wheel well area of an automobile includes a carrier (12) and a load distributing medium supported by the carrier (12). The carrier (12) also may include a reinforced protrusion (28), reinforced openings (32), and an outwardly extending flange (22). The flange (22) includes a reinforced raised portion having a shape similar to that of the flange (22). The load distributing medium is a structural foam (14) and preferably an epoxy-based resin.

Description: STRUCTURAL REINFORCEMENT MEMBER FOR WHEEL WELL FIELD OF THE INVENTION The present invention relates generally to a structural reinforcement member for use in increasing the stiffness and strength of a frame assembly, such as an automobile frame. More particularly, the invention relates to a reinforcement member that reinforces the frame using a heat-activated structural foam, and carrier wherein the composite of the carrier and activated foam increases the structural stiffness and strength of the frame. BACKGROUND OF THE INVENTION For many years the automobile industry has been concerned with designing frame reinforcement members that do not add significantly to the weight of the automobile. United States Patent Nos. 5,755,486; 4,901 ,500; and 4,751 ,249 describe prior art reinforcing devices. While these prior art devices may be advantageous in some circumstances, there is needed a simple low cost structure that permits coupling the reinforcement member to a variety of structures of varying geometric configurations. SUMMARY OF THE INVENTION The present invention is directed to a structural reinforcement member designed for reinforcing a wheel well portion of an automobile frame. The reinforcement member includes a polymeric carrier, which may be amenable to injection molding or other such moldable material such as polymeric, metallic, or ceramic, and a load distributing medium disposed on the carrier. In one embodiment, the carrier supports a reinforced protrusion and two reinforced openings. Additionally, the carrier supports an outwardly extending flange. The flange includes a reinforced raised portion having a shape similar to that of the flange. The load distributing medium disposed on the carrier is a structural foam, and is preferably an epoxy-based resin. The preferred load distributing medium is L5206, L5207, L5208, or L5209 structural foam, which is commercially available from L&L Products of Romeo, Michigan. During an automobile assembly process the reinforcement member is positioned against the automobile frame so that the uncured structural foam is against the wheel well portion. Once the foam is cured, the reinforcement member adheres to the frame and distributes any loads that impact the wheel well portion of the automobile frame. BRIEF DESCRIPTION OF THE DRAWINGS The features and inventive aspects of the present invention will become more apparent upon reading the following detailed description, claims, and drawings, of which the following is a brief description: FIG. 1 is a front perspective view of a structural reinforcement member. FIG. 2 is a front elevational view of the structural reinforcement member shown in FIG. 1. FIG. 3 is a rear elevational of the structural reinforcement member shown in FIG. 1 . FIG. 4 shows a top plan view of the structural reinforcement member shown in FIG. 1. FIG. 5 shows an assembly view of the structural reinforcement member of FIG. 1 installed in the wheel well portion of an automobile frame. DETAILED DESCRIPTION OF PREFERRED EMBODIMENT FIG. 1 shows a structural reinforcement member 10 formed in accordance with the teachings of this invention. The reinforcement member 10 includes a carrier 12 and a load distributing medium 14 supported by the carrier 12. The carrier 12 can be formed of a polymeric material, a preferred polymeric material being nylon, but may also consist of a metallic or ceramic material. More preferably the nylon material is a thirty-three percent glass filled nylon. However, it will be appreciated that other materials having similar properties may be used. One advantage of the carrier 12 being fabricated of a moldable material is the ability to mold the carrier 12 into a variety of configurations. Specifically, the carrier 12 can be fabricated using a mold having virtually the same configuration as the frame portion to which the reinforcement member 10 will be coupled. This facilitates assembling the reinforcement member 10 with the automobile frame without the need for mechanical fasteners or welding. The carrier 12 is a four-sided structure having a square configuration, and includes a front surface 16, an opposing rear surface 18, and opposing side surfaces 20. It will be appreciated that other suitable geometric configurations may be used to form the carrier 12. For example, the carrier 12 may be rectangular, circular, or a variety of complex geometrical configurations. The particular configuration chosen for the carrier 12 will vary depending on the configuration of the area being reinforced. In the disclosed embodiment, the front surface 16 is surrounded by opposing sides 20 and rear surface 18, wherein the rear surface 18 is reinforced by a lattice network 31. The front surface 16 supports a raised circular protrusion 28 that is also reinforced by a lattice network 26. It is contemplated that the lattice network 26 may consist of a matrix type design which provides nearly the same level of reinforcement as a solid structure. Adjacent the protrusion 28, the lower portion 23 of the front surface 16 supports and is reinforced by a lattice structure 30. The front surface 16 also includes a pair of reinforced openings 32, and an integrally formed flange 22. The flange 22 projects outwardly from an end portion of the front surface 16 along a radius 17 formed at a location adjacent one of the opposing sides 20. The flange 22 supports an outward projection 34. The flange 22 also includes an upper portion 40, which tapers to a narrower strip 42 that projects outwardly from and extends along the outer perimeter of the flange 22. The outward projection 34 supports a lattice portion 36 having a configuration virtually similar to that of the outward projection 34. The structural strength and stiffness of the carrier 12 is increased by applying the load distributing medium 14 to selected surfaces of the carrier member 12. In the preferred embodiment, the load distributing medium 14 is a structural foam applied to the front surface 16. The structural foam 14 increases the strength and structural stiffness of the carrier 12 without adding significantly to the overall weight of the carrier 12. Typically, the structural foam 14 is applied to the carrier 12 in the areas corresponding to frame areas where reinforcement is desired such as a continuous load transfer medium or bonding surface application. In the embodiment shown, the structural foam 14 is applied to the top surface 20 and the sidewall 18. The structural foam 14 is preferably heat-activated and expands upon heating, typically by a foaming reaction. The structural foam 14 is generally applied to the carrier 12 in a solid or semi-solid state. The structural foam 14 may be applied to the outer perimeter of the carrier 12 in a fluid state using commonly known injection techniques, wherein the structural foam 14 is heated to a temperature that permits the structural foam 14 to flow slightly. Upon cooling the structural foam 14 hardens and adheres to the outer surface of the carrier 12, either via a separate adhesive layer (not shown) or via adhesive characteristics in the structural foam 14 formulation itself. Alternatively, the structural foam 14 may be applied to the carrier 12 as precast pellets, which are heated slightly to permit the pellets to bond to the outer surface of the carrier 12. At this stage, the structural foam 14 is heated just enough to cause the structural foam 14 to flow slightly, but not enough to cause the structural foam 14 to expand. Note that other expandable materials can be used, such as, without limitation, an encapsulated mixture of materials that, when activated by temperature, pressure, chemically, or other by other ambient conditions, will expand. The structural foam 14 is preferably an epoxy-based material, but may include other polymers such as ethylene copolymers or terpolymers. A copolymer or terpolymer, is composed of two or three different monomers, i.e., small molecules with high chemical reactivity that are capable of linking up with similar molecules. A number of epoxy-based structural reinforcing foams are known in the art and may also be used to produce the structural foam 14. A typical structural foam includes a polymeric base material, such as an epoxy resin or ethylene-based polymer which, when compounded with appropriate ingredients (typically a blowing agent and curing agent), expands and cures in a reliable and predicable manner upon the application of heat or the occurrence of a particular ambient condition. The resulting material has a density that is sufficient to impart desired rigidity to a supported article. From a chemical standpoint for a thermally-activated material, the structural foam 14 is usually initially processed as a thermoplastic material before curing. After curing, the structural foam 14 typically becomes a thermoset material. An example of a preferred structural foam 14 formulation is an epoxy-based material including an ethylene copolymer or terpolymer and an alpha-olefin that is commercially available from L&L Products of Romeo, Michigan, under the designations L5206, L5207, L5208 and L5209. One advantage of the preferred structural foam materials 14 over prior art materials is that the preferred materials can be processed in several ways. The preferred materials can be processed by injection molding, extrusion or with a mini-applicator type extruder. This enables the formulation and creation of part designs that exceed the capability of most prior art materials. While the preferred materials for fabricating the structural foam 14 have been disclosed, the structural foam 14 can be formed of other materials provided that the material selected is heat-activated or otherwise activated by an ambient condition (e.g. moisture, pressure, time or the like) and expands in a predictable and reliable manner under appropriate conditions for the selected application. Some other possible materials include, but are not limited to, polyolefin materials, copolymers and terpolymers with at least one monomer type an alpha-olefin, phenol/formaldehyde materials, phenoxy materials, and polyurethane materials with high glass transition temperatures. See also, U.S. Patent Nos. 5,766,719; 5,755,486; 5,575,526; and 5,932,680, the disclosures of which are incorporated herein by reference. In general, the desired characteristics of the structural foam 14 include high stiffness, high strength, high glass transition temperature (typically greater than 70 degrees Celsius), and good corrosion resistance properties. In applications where a heat activated, thermally expanding material is employed, an important consideration involved with the selection and formulation of the material comprising the structural foam 14 is the temperature at which a material reaction or expansion, and possibly curing, will take place. For instance, in most applications, it is undesirable for the material to be reactive at room temperature or otherwise at the ambient temperature in a production line environment. More typically, the structural foam 14 becomes active at higher processing temperatures, such as those encountered in an automobile assembly plant, when the foam 14 is processed along with the automobile components at elevated temperatures or at higher applied energy levels. While temperatures encountered in an automobile assembly operation may be in the range of 148.89 °C to 204.44 °C (300 °F to 400 °F), body and paint shop applications are commonly about 93.33 °C (200 °F) or slightly higher. Generally, prior art expandable foams have a range of expansion ranging from approximately 0 to over 1000 percent. The level of expansion of the structural foam 14 may be increased to as high as 1500 percent or more. Higher expansion, now ever, typically results in mechanical property reduction. The reinforcement member 10 may be used in numerous applications where structural reinforcement is desired. More particularly, the reinforcement member 10 has particular application in those instances where the overall weight of the structure being reinforced is a critical factor. For example, the reinforcement member 10 may be used to reinforce the frames of automobiles, airplanes, boats, building structures and other similar objects. Fig. 5 illustrates the reinforcement member 10 being installed in a wheel well portion 44 of an automobile frame 46. As can be seen in the figure, the reinforcement member 10 fits against the wheel well portion 44 so that the load distributing medium 14 is in contact with the frame 46. The load distributing medium 14 is then cured in the course of the automotive assembly process. Once the load distributing medium 14 is cured, the structural foam 14 expands along the front surface 16 and fills the gap 46 surrounding the circular protrusion 28. When placed adjacent a structure to be reinforced, i.e., the wheel well 44, the cured structural foam acts as an adhesive and thus bonds the reinforcement member 10 to the element being reinforced. The structural foam 14 is fully cured by subjecting the reinforcement member 10 to temperatures in the range of those generated by a paint oven of the type used to cure automobile body paint or primer. It will be appreciated that paint ovens are known to reach minimum temperatures of 93.33 °C (200 °F) or greater. Thus, it will be appreciated that the structural foam 14 may be cured by simply heating the reinforcement member 10 to a temperature of 93.33 °C (200 °F) or greater. The curing of the structural from 14 increases the structural strength and stiffness of the carrier 12. As a result, the overall structural strength and stiffness of the reinforcement member 10 is increased. The preferred embodiment of the present invention has been disclosed. A person of ordinary skill in the art would realize, however, that certain modifications would come within the teachings of this invention. Therefore, the following claims should be studied to determine the true scope and content of the invention.

Claims: CLAIMS WHAT IS CLAIMED IS: 1. A structural reinforcement member for reinforcing a frame assembly, comprising: a carrier adapted to fit into the frame, the carrier having a front surface and a rear surface; and a load-distributing medium supported by the carrier on at least the front surface for contacting and adhering to the frame. 2. The structural reinforcement member of Claim 1 , wherein the carrier includes a reinforced protrusion on the front surface. 3. The structural reinforcement member of Claim 1 or Claim 2, wherein the carrier supports an outwardly extending flange. 4. The structural reinforcement member of any of the preceding Claims, wherein the carrier comprises a polymeric material having moldable characteristics. 5. The structural reinforcement member of any of the preceding Claims, wherein the carrier is comprised of nylon. 6. The structural reinforcement member of any of the preceding Claims, wherein the load-distributing medium is a structural foam. 7. The structural reinforcement member of Claim 6, wherein the structural foam is formed from a polymeric material having curing agent characteristics. 8. The structural reinforcement member of Claim 6 or Claim 7, wherein the structural foam is formed from an epoxy-based resin. 9. A structural reinforcement member according to any of the preceding Claims, wherein the load distributing medium is a structural foam supported by the front surface of the carrier. 10. The structural reinforcement member of any of the preceding Claims, wherein the front surface is supported by a lattice structure. 1 1 . A structural reinforcement member according to any of the preceding Claims, for reinforcing a surface portion of a vehicle frame, comprising: a carrier having a front surface with a configuration that substantially conforms to the surface portion of the vehicle frame and a protrusion on the front surface that is adapted for insertion into an aperture in the surface portion of the vehicle frame; and a load distributing medium applied to the front surface of the carrier and configured to contact the surface portion of the vehicle frame, such that heat activation initiates flow of the load distributing medium and cooling cures the load distribution medium and adheres the carrier to the surface portion of the vehicle frame. 12. A structural member according to any of the preceding Claims, for reinforcement of a wheel well of an automobile frame. 13. A reinforced portion of a vehicle frame, comprising: a surface of the portion of the vehicle frame having an aperture; a molded plastic carrier having a contact wall with a contact surface that substantially conforms to the surface of the portion of the vehicle frame and a protrusion adapted for insertion into said aperture; a lattice structure projecting from said contact surface; a structural foam on said contact surface, said structural foam adhering said contact surface to said surface of the portion of the vehicle frame such that said molded plastic carrier and said lattice structure are coupled to the surface of the portion of the vehicle frame. 14. The structurally reinforced portion of the vehicle frame of Claim 13, wherein said contact wall is generally planar. 15. A method for reinforcing a wheel well portion of an automobile frame, comprising the steps of: providing a structural member containing the wheel well portion; coupling a reinforcement member to the wheel well portion of the structural member, wherein the reinforcement member includes a carrier and a load distributing medium supported by the carrier; and activating the load-distributing medium by changing a predetermined ambient condition. 16. A method according to Claim 15, in which the reinforcement member is a structural member according to any one of Claims 1 to 12. 17. A method according to Claim 15 or Claim 16, in which the ambient condition is temperature. 18. A method for reinforcing a surface portion of a vehicle frame, comprising: providing the surface portion of the vehicle frame with an aperture; inserting into the aperture a protrusion on a molded plastic carrier having a structural foam on a contact surface thereof; initiating flow and foaming of the structural foam by increasing the temperature of the structural foam from an ambient temperature to an increased temperature; and reducing the temperature of the structural foam from the increased temperature such that the expanded structural foam rigidifies and adheres the molded plastic carrier to the surface portion of the vehicle frame. 19. A method according to Claim 18 in which the increase in the temperature of the structural foam is accomplished in the vehicle manufacturing process.

Inventors: BARZ WILLIAM J, BARZ, WILLIAM, J.
Applicants: L & L PRODUCTS INC, L & L PRODUCTS, INC.
Application year: 2001
Main classification: B62D29
IPC codes: B62D21, B62D29