Source: http://www.freepatentsonline.com/8163211.html
Timestamp: 2017-10-19 07:28:51
Document Index: 504783491

Matched Legal Cases: ['Application No. 07767648', '§371', 'Application No. 2007', 'arts 28', 'arts 28', 'arts 28', 'art 28', 'arts 28', 'art 28']

Panel and method for manufacturing the same - Caterpillar S.A.R.L.
United States Patent 8163211
11/997335
Caterpillar S.A.R.L. (Geneva, CH)
156/77, 156/78, 156/79, 264/41, 264/45.1, 264/45.5, 264/45.6, 264/46.4, 264/46.6, 264/46.7, 264/46.9, 428/36.5, 428/158, 428/304.4, 428/309.9
B29C65/00; B29C44/04; B29C67/00; B29D22/00
156/79, 156/77, 156/78, 264/46.4, 264/46.5, 264/46.6, 264/46.7, 264/46.9, 264/41, 264/45.1, 264/45.5, 264/45.6, 428/36.5, 428/158, 428/304.4, 428/309.9
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20060006698 Automobile hood 2006-01-12 Ishikawa et al.
20040041429 Composite panel and method of forming the same 2004-03-04 McLaren et al. 296/57.1
5866052 Process of manufacturing structural body for automotive vehicle 1999-02-02 Muramatsu 264/46.6
5649400 Support structure for supporting foamable material on hollow structural member 1997-07-22 Miwa
4916284 Method of making hemmed joints utilizing laser welding 1990-04-10 Petrick 219/121.64
4857698 Laser perforating process and article produced therein 1989-08-15 Perun 219/121.71
4578436 Coating resinous composition containing saturated alicyclic acid modified amphoteric polyester resin 1986-03-25 Umemoto et al. 525/443
4378395 Reinforcing material 1983-03-29 Asoshina et al. 428/158
JP61191954 November, 1986 METAL OXIDE THIN FILM GAS SENSOR ELEMENT
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JP09302717 November, 1997 ENGINE COVER FOR CONSTRUCTION MACHINERY
JP10258331 September, 1998 METHOD FOR JOINING CAR BODY PANELS AND JOINING STRUCTURE THEREFOR
JP2001122052A 2001-05-08 METHOD OF MANUFACTURING PANEL STRUCTURE BODY FOR TRANSPORT AIRPLANE EXCELLENT IN SOUND INSULATING PROPERTY
JP2001301659A 2001-10-31 AUTOMOBILE PANEL COMPONENT
WO2004013214A1 2004-02-12 MULTIPLE MATERIAL ASSEMBLY FOR NOISE REDUCTION
JPH09302717A 1997-11-25
JPH09228412A 1997-09-02
JPH10258331A 1998-09-29
JPS61191954A 1986-08-26
Extended European Search Report issued for corresponding European Patent Application No. 07767648.6 mailed on Dec 15, 2009.
1. A method for manufacturing a panel comprising the steps of: spraying a coating material onto an outer thin plate; providing a non-foam material of a foamable filler on the outer thin plate; providing an inner thin plate over the outer thin plate to form a space between the inner and outer plates, wherein the space contains the non-foam material; intermittently applying a thermosetting adhesive to a perimetrical edge part of the outer thin plate, wherein the adhesive is partially and intentionally removed from the perimetrical edge part; turning up the entire perimetrical edge part of the outer thin plate to fix the perimetrical edge part to a perimetrical edge part of the inner thin plate; placing the fixed assembly into a baking coating heating device to bake the coating material and foam the non-foam material so that it fills into the space; simultaneously curing the adhesive with the baking coating heating device; and releasing air contained in the space during foaming through omissions of the adhesive.
2. The method for manufacturing the panel according to claim 1, further comprising the steps of: drilling an inner hole in the inner thin plate; and laser processing an outer hole to the outer thin plate through the inner hole.
This is a U.S. national phase application under 35 U.S.C. §371 of International Patent Application No. PCT/JP2007/062742 filed Jun. 26, 2007, and claims the benefit of Japanese Application No. 2007-005524, filed Jan. 15, 2007. The International Application has not been published at the time of this filing. The contents of these applications are incorporated herein in their entirety.
There has been a cover body structure obtained by welding an inner reinforcing plate having a concave part to an outer panel of construction machinery (for example, see Japanese Patent Application Laid-Open No. 09-228412 (“JP '412”) (e.g., page 3, FIG. 7)).
There has been an engine cover having a sound insulating material or a sound absorbing material as a lining member attached to the inner side of a cover body in construction machinery (for example, see Japanese patent Publication No. 3457804 (“JP '804”) (e.g., page 2, FIG. 1)).
Next, as shown in FIG. 3(a), referring to a method for manufacturing the panels 17 and 18, non-foam materials 24a of the foamable filler are provided on the outer thin plate 21. The inner thin plate 23 forming the space 22 corresponding to the non-foam materials 24a is fixed to the outer thin plate 21. At this time, a thermosetting adhesive is supplied between contact surfaces of the outer thin plate 21 and inner thin plate 23. The non-foam materials 24a are stuck on the outer thin plate 21 so that a plurality of rubber sound absorbing materials are arranged at a proper interval in one space 22.
The adhesive is cured by a baking coating heating device. Furthermore, as shown in FIGS. 3(b) and 3(c), the non-foam materials 24a are foamed by the baking coating heating device to fill the foam materials 24 in the space 22. Coating materials previously sprayed on the outer thin plate 21 and the inner thin plate 23 are baked by the baking coating heating device.
For example, it is necessary to heat the adhesive at 150° C. for 5 minutes in order to cure the adhesive; it is necessary to heat the foam material 24 at 180° C. for 20 minutes in order to complete the foam formation of the foam material 24; and baking heating at 200° C. for 20 minutes is required in order to complete the baking coating. Thereby, all the heatings can be performed by using the existing baking coating heating device.
In the manufacture of the panel 17 shown in FIG. 5(a), a thermosetting adhesive 38 is applied onto three perimetrical edge parts 28b, 28c, 28d, 28e and 28f of a right and left side edges and lower side edge among perimetrical edge parts 28a, 28b, 28c, 28d, 28e and 28f of the outer thin plate 21. As shown in FIG. 5(b), the entire perimetrical edge parts 28a to 28f of the outer thin plate 21 are turned-up without applying the thermosetting adhesive 38 onto the perimetrical edge part 28a of the upper side edge, and the perimetrical edge parts 28a to 28f are fixed to the perimetrical edge part of the inner thin plate 23.
As shown in FIG. 3, since the non-foam material 24a of the foamable filler set on the outer thin plate 21 is foamed by the baking coating heating device to fill the foam material 24 in the space 22 of the inner thin plate 23, the non-foam material 24a can be efficiently foamed in the baking coating. Thereby, the manufacturing efficiency can be enhanced, and the baking coating heating device can be efficiently operated.
Furthermore, the thermosetting adhesive can be efficiently cured upon baking coating by the baking coating heating device, and the non-foam material 24a can be efficiently foamed. Thereby, the manufacturing efficiency can be enhanced, and the baking coating heating device can be efficiently operated.
As shown in FIG. 5, air can be removed when the non-foam material 24a of the foamable filler is foamed from the non-applied part of the adhesive 38 by intermittently applying the adhesive 38, and partially and intentionally removing the adhesive 38 to partially omit the application of the adhesive 38 when the adhesive 38 is applied onto the perimetrical edge part of the outer thin plate 21. Therefore, a smooth foaming operation can be secured, and the generation of problems of thin plate burst or the like in complete sealing can be prevented.
In one example shown, referring to the side door panel used for a conventional hydraulic backhoe, a thick sheet metal having a thickness of 1.6 mm is further reinforced. On the other hand, as the outer thin plate 21, a thin sheet metal having a thickness of 0.8 to 1.2 mm is used, and as the inner thin plate 23, a thin sheet metal having a thickness of about 0.35 to 0.6 mm is used. The thin plates 21 and 23 are laminated using an adhesive. The thin plates 21 and 23 are sealed by the perimetrical edge part 28 formed by turning up the perimetrical edge part of the outer thin plate 21. The non-foam material 24a of a foamable rubber sound absorbing material is laminated on the inner surface of the outer thin plate 21 facing the space 22 between the thin plates 21 and 23 before laminating them. This non-foam material 24a is foamed in a heat process in baking the coating so that the material is filled in a part or all of the space 22. Since the foam material 24 has reinforcing effect and sound absorbing performance, even a large-sized panel can suppress the weight to attain weight reduction and can enhance sound insulating performance and strength. The panel can strengthen the rigidity of a door, can substantially realize a reduction in noise of a standard door, and has excellent appearance.
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