CN1187792A - 复合结构的增强元件 - Google Patents

复合结构的增强元件 Download PDF

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CN1187792A
CN1187792A CN96194078A CN96194078A CN1187792A CN 1187792 A CN1187792 A CN 1187792A CN 96194078 A CN96194078 A CN 96194078A CN 96194078 A CN96194078 A CN 96194078A CN 1187792 A CN1187792 A CN 1187792A
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J·S·维塞克
B·L·哈里桑
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Abstract

一个增强的结构元件(18)含有一个w－形的装载可热发泡的树脂基材料(36)的增强元件(32)。该w－形增强元件(32)放置在一个中空结构元件(20)的通道中并位于一根穿过该增强元件(32)的槽的销钉(30)的上面。加热结构元件(20),让树脂基材料(36)发泡以便将增强元件(32)定位,从而显著地增强该结构元件。

Description

复合结构的增强元件
技术领域
本发明一般性涉及汽车车身结构元件，更具体地说，涉及用来增加汽车车身结构元件的强度的增强元件。
背景
在大量的设计应用尤其在汽车工业中，提供重量轻并且具有高强度特征的结构元件是极其重要的。过去其它领域已经建议使用许多种奇特的金属合金及其类似物来形成高强度的结构元件；然而，在一些应用中，包括汽车工业，这些合金的价格通常是不能接受的。因此，需要重量轻，价格低并且能替代现有设计结构的结构增强元件。
现有技术中有一种值得注意的车身，其涉及到对机动车结构组件的增强。在题为“轻重量的复合横梁”的U.S.P.No.4,901,500中公开了一种机动车车门的增强横梁，该横梁包括一个开放的通道形金属元件，元件中有一个用热固或热塑性树脂基材料填充的纵向空腔。在题为“制备扭杆的方法”的U.S.P.No.4,908,930中描述了一种用含有填料的树脂的混合物增强的中空扭杆。管子被切成一定长度并用树脂基材料装填。
在题为“一种结构元件的增强插件及其制备与使用方法”的U.S.P.No.4,751,249中提供了一种由大量的含有热固性树脂和发泡剂的粒料所形成的结构元件的预浇铸增强插件。将预铸件在结构元件中发泡并固化定位。在题为“由位于管中间的合成泡沫芯增强的复合管状门梁”的U.S.P.No.4,978,562中描述了一种含有不超过金属管腔的三分之一的树脂基芯的复合门梁。
在题为“用于汽车车身结构的复合层板状横梁”的1994年5月19日立挡的正在审查当中的U.S.P.申请序列No.245,798中描述了一种中空层板状横梁，其特征在于具有高刚性-质量比并且有一个由一薄结构泡沫层与内管分开的外部。
虽然一些应用中对立于以往技术中的增强技术有了一些改进，仍然有必要采用一种不仅花费低而且在大量生产装配中容易接受的方法来对横梁部位进行增强，以便显著性也增加横梁的强度，特别是在受力点。
还有，已经知道氰基胍是一种常用的已发泡的环氧聚合物的潜在固化剂。最频繁使用的材料的规定颗粒大小约80微米。对于高活性的情况，有时采用微粉化的变化形式，比如90％的颗粒低于30微米。以往技术中，固化剂的普通使用方法往往导致发泡聚合物的“焦烧”。这是因为由固化反应所放出的热不容易扩散。然而，将烘箱的温度设置在其它的条件(比如油漆固化之类)时溶液是不能用的。
发明概述
一方面，本发明提供了一种增强的结构元件。该增强的结构元件中有一个放置增强元件的纵向的空腔。增强元件中含有一条让销钉或其它约束工具延伸穿过的槽。销钉被固定在结构元件中相对的侧壁上。增强元件的壁是开放的，并且增强元件里面用树脂基材料填充。增强的结构元件通过将销钉定位然后在销钉上面插上用树脂基材料填充的增强元件来装配。增强元件和其中的树脂基材料的开放面与结构元件的侧壁相邻，销钉穿过增强元件的开放槽。让含有机动车横梁的结构元件移动穿过烘箱，使树脂基材料发泡并与结构元件的侧壁相粘结，从而与结构元件的内壁形成坚固的粘结。发泡的树脂基材料有效地生成一个包括增强元件，发泡的树脂和结构元件的简单的一体化结构。
另一方面，增强元件的开口处与结构元件的底部相邻容许树脂扩展穿过开口并与结构元件的另一面粘结，从而使增强元件与结构元件更劳固地粘结在一起。
再有一个方面，本方面提供了一种新的含环氧树脂，弹性材料，填料，煅制二氧化硅，高强度的玻璃球，以及固化剂，促进剂和发泡剂的环氧树脂基增强材料。
本发明中，结构元件的总强度显著地增加，增强元件所处地方的开裂减少。
附图的简单说明
图1是由一个本发明所增强的横梁元件的一个部位的透视图。
图2是图1中的横梁元件被部分切开后的侧视图，用来说明增强元件和横梁的位置。
图3是结构增强托架元件在插入图1和图2中的中空结构元件之前的透视图。
图4是图3沿线4-4的截面图。
图5是插入增强元件前含横向增强杆的中空结构元件的透视图。
图6是一个部分切开的按本发明的另一种实施方案来增强的中空框的侧视图。
图7是图6中的增强元件沿线7-7的截面图。
图8是图3中的增强元件不含树脂基芯时的透视图。
图9是本发明中使用的另一种构型的增强元件的侧视图。
图10是本发明中使用的另一种构型的增强元件及其所带的销钉的侧视图。
图11是图1所示结构去掉树脂基芯后的平面视图。
图12是本发明中使用的另一种构型的增强元件的侧视图。
优选实施方案详细说明
现在参照附图1，可以看出增强的结构18中有含顶面或封面22(想象中有)的中空结构元件20。结构元件20中含面对着的侧壁24和26及底面28，因此是一个通道状的元件。如附图5中所示，销杆或销钉30架在侧壁24和26之间。销钉30起缓冲作用的装置并作为增强元件32的固定元件。增强元件32放置在中空结构元件20的纵向空腔34中并有一个作为树脂基增强/粘结材料36的托架或容器的托架部分33(如图8所示)。附图2中，侧壁24被部分切开以便说明增强元件32和销钉30的端部。
中空结构元件20优选是由金属比如钢作成，且更优选是一根机动车的横梁。而且，在最优选的实施方案中，增强的结构元件18是一根汽车横梁。
现在参照附图3，4和8，托架33有外侧壁38和40，内侧壁42和44，底壁46和48以及一个连接壁50，从而确定了两个通道形的空腔52和54。如图4和8所示，这些壁确定了一个C-形的树脂接受空腔56。通过这种方式，树脂基增强/粘结材料36形成一个C-形树脂体结构或芯58。
可以理解的是许多种几何形状适合于用作托架33，作为优选的W-设计或构型只是这些构型中的一种。比如在一种给定的应用中，图9中所示的波浪形构型70或图10中所示的有树脂基外部涂层(即无外侧壁)的倒U-形结构72是适合的。如图12所示，完全去掉托架33而用一个不固定的树脂体74也是适合的。增强元件32中通常含有足够的容纳或支撑树脂基增强体的装置和与象销钉30一样的定位保留装置结合的装置。最优选地，托架33将在确定一个或几个树脂基增强/粘结材料的储存点或容器的同时，还拥有让树脂基增强/粘结材料发泡并与中空结构元件20的侧壁24和26粘结的开口。
托架33的尺寸或厚度可以不同，但通常在0.025和0.060之间。增强元件32的尺寸应该与通道34近似地匹配以至于托架33与侧壁24和26之间至少有一些点相接触，但在装配期间为了插入增强元件并不需要扩展通道34。销钉30优选是金属的，并且如上所述，通过与由托架33的内侧壁42，44和连接壁50所确定的槽60相结合而将增强元件32定位。最优选是销钉30和槽60之间的任何空隙应该足够小以至于增强元件32在树脂基增强/粘结材料36发泡之前不会显著地移动。树脂基增强/粘结材料36的组成以及增强的结构元件18的装配方法将在以下进行更全面的描述。
在本发明的又一个实施方案中，现在参照附图6和7，可以发现增强元件32′中有许多在装配过程中的发泡期间让树脂基材料36′流过的开口或通道62。这在中空结构元件20的底面28′上形成了另外的粘结区64。通过以这种方式提供开口62，使增强的结构18获得更多的粘结并增加了强度。在这个实施方案中，增强的结构元件18的所有其它特征与图1～5中所示的实施方案中所描述的有关特征相同。
许多种材料可以适合于用来形成树脂基增强/粘结材料38。适宜的材料应该是当其未固化或部分固化时具有足够的形态以至于一旦形成时并在插入通道34之前材料不会显著地从托架33中流出。因此，最好是托架33先在一个准备步骤中容纳树脂基增强/粘结材料36以便形成一个随后插入通道34中的部件。除了足够的形态外，重要的是树脂基增强/粘结材料36不断地发泡与侧壁24和26接触(在图6和图7所示的实施方案中还有底面28)，并且这种不断的发泡提供了所需要的压强。树脂基增强/粘结材料36牢固地粘结在托架33的内表面以及侧壁24和26上也是重要的。树脂基增强/粘结材料36也必须有足够的热稳定性以便在经受油漆固化烘箱之类的温度时不会分解。树脂基增强/粘结材料36也必须是重量轻和花费低，并且通常应该对增强的结构元件18产生良好的机械强度。
更具体地，树脂基增强/粘结材料36的密度在完全固化前应该是约35磅/立方尺～约65磅/立方尺，而一旦完全发泡定位后约25磅/立方尺～45磅/立方尺。树脂体58的压强(发泡和固化后)应该至少1000磅/平方寸，更优选约1500磅/平方寸或更大。树脂体58与侧壁24和26间(其中侧壁24和26是钢)的粘结应该足以保持金属/固化粘结之间的强度。这使得树脂体58很难从侧壁24和26以及托架33上分离。固化的树脂体58短期间无显著的施压时应该能够经受超过450°F的温度并且长时间经受175°F以上的温度而不出现明显的热变形或分离。
树脂体58可通过封闭托架33的开口侧壁39和41并注入或倾入一种类似于树脂基材料的液体或浆料而在托架33中形成。然后材料36可通过固化或冷却来硬化。另外，树脂体58可预先形成然后再插入由托架33所确定的容纳树脂的空腔56中。
一种优选的用作树脂基增强/粘结材料36的材料包括合成树脂，可发泡性自发泡剂，以及填料。除非另有说明，这里所有的百分数都是重量百分数。在一个实施方案中，合成树脂约占树脂体58的45％～70wt％，优选是约50％～约60wt％。蜂窝状结构是最优选的，因为它提供低密度，高强度的材料，这种材料而强度高重量轻。自发泡剂可包括一种诸如偶氮二酰胺或P，P′-氧-双(苯磺基酰肼)之类的化学发泡剂，约占树脂体58的0.1％～10wt％，更优选是约0.5％～约2wt％。此外，在一些应用中，优选可使用热固性或热塑性的并且直到增强的结构元件被加热以发泡材料36时才发泡的塑料微球。可以理解，直到增强元件32处于通道34中后材料36才被完全发泡。发泡剂用作自发泡剂时，它们约占树脂体58的0％～10％且更优选是约1.5～约3wt％。有许多种适合的填料，包括玻璃或塑料微球，煅制二氧化硅，碳酸钙，磨碎的玻璃纤维和短玻璃纤维。填料约占树脂体58的20％～50wt％，更优选是约25％～约40wt％。
本发明中使用的优选的合成树脂包括诸如单组分环氧树脂，乙烯基酯树脂，热固性聚酯树脂以及聚氨酯树脂之类的热固性塑料。这种树脂组分的平均分子量(数量平均)约1000～5000000。当材料36的树脂组分是一种热固性树脂时，包括诸如改性的尿素塑料和三氯化硼之类的各种促进剂。一种诸如双氰胺之类的固化剂被用来固化树脂。促进剂的使用量一般约为树脂重量的0.1～5％，并相应地减少树脂、自发泡剂或填料这三种组分中的一种。一些热塑性塑料也是适合的。
一种用作材料36并包括本发明的另外一个方面的的最优选的组合物是一种如上所述放置在托架33中的高粘度的“生面团”形式的未固化的单组分环氧体系。对于优选的单组分环氧生面团，未固化材料36从而增强元件32可用碱或酸性溶液进行洗涤、磷酸酯化或其它处理而不显著地破坏材料36。因此，在这个实施方案中的材料36在其未固化状态下耐酸和碱。尤其在汽车应用中这种性质容许将增强元件32在早期阶段插入生产线中。
而且，在一个优选的实施方案中，材料36含(重量百分数)约30％～70％的环氧树脂，约0％～20％的诸如聚丁基橡胶，丙烯腈-丁二烯橡胶(ABR)或聚异戊二烯之类的弹性体，约1％～30％的诸如碳酸钙，煅制二氧化硅，高强度玻璃微球之类的填料和约0％～10％的诸如偶氮二酰胺或P，P′-氧-双(苯磺基酰肼)之类的发泡剂。
此外，材料36进一步包括约2％～10％的诸如双氰胺或氰基胍之类的固化剂。已经发现颗粒固化剂的大小是材料36的优选配方的一项重要的特性。通过提供粉状或粒状的其中40％的颗粒直径大于15微米的固化剂，与材料36的其它成分调配，即使是经受汽车点火器中的温度也不发生有热分解的固化。换句话说，通过使用含氰基胍的调和物的高粗糙颗粒含量的单组分环氧树脂，固化的环氧泡沫物内部未出现“焦烧”或“焦烧”水平减轻。
材料36中优选也包括约0％～5％的诸如改性的尿素塑料或三氯化硼之类的促进剂。也包括约0％～10的炭黑。
在最优选的实施方案中，材料36包括约1％～6％的疏水性氧化硅和约18～27％的高强度的直径约20～400微米的玻璃球。高强度球的硬度(耐破碎性)至少500psi。
最优选的环氧树脂是固体双酚A和固体双酚F(包括液体环氧树脂)。一种这样的环氧树脂是Peninsula Polymer Company销售的DGEBPA树脂。
最优选的弹性体是Kentucky的Zeon Company以NIPOL1312销售的丙烯腈-丁二烯橡胶。
一种优选的填料是Massachusetts的Zeneca Company以WINNOFIL销售的经硬脂酸处理的碳酸钙。
优选的煅制二氧化硅是由Illinois的Cabot Company销售的CAB-O-SILTS 720。
优选的高强度玻璃球是由Minnesota的3M Company销售的B38 GlassBubbles。
最优选的固化剂、固化促进剂和发泡剂分别是由Georgia的SKW销售的双氰胺G，AMICURE UR(Pennsylvania的Air Products Company)和CELOGEN OT(Connecticut的Uniroyal Company)。
在最优选的实施方案中，准备材料(未固化的)36应该有类似于生面团的稠性。材料36可通过诸如将各种组分混合在一起之类的普通方法来制备。
下表中提出了一个树脂基增强/粘结材料36的优选配方。将注意到该配方仅仅是优选的，在特定的应用中可以使用其它的配方。
表I
                                    WT.  ％
环氧树脂                            50.45
丙烯腈-丁二烯橡胶                    4.33
碳酸钙                               5.81
碳黑                                 0.13
煅制二氧化硅                         3.55
高强度玻璃球                        22.40
固化剂                                4.33
促进剂                                1.29
发泡剂                                0.71
至于增强的结构元件18的装配，现在参照附图1和3，象前面所描述的那样制备树脂基增强/粘结材料36并放置在托架33中。一次可制备许多个填充的增强元件32并保存起来供将来使用。可以理解的是增强元件32插入通道34时，树脂基增强/粘结材料36的粘度很高以至于保持在增强元件32内，但还能发泡并完全固化或固化以便在通道34内与托架33组合形成一种坚硬的结构(树脂体58)。用钻头穿过内壁24和26并插入销钉30。最好是销钉30的作用在于将增强元件32定位在通道34中，且在给定的应用中诸如小块之类的仅仅从每个对立的内壁24和26部分延伸的加固装置是适合的或希望的。其它的固定装置也是适合的。优选地，销钉30是如图5所示那样焊接穿过通道34，从而为结构18提供强度。
将增强元件32插入通道34中，让销钉30填入槽60中，从而将增强元件32固定(即限制增强元件32沿通道34纵向移动)。在图1中所示的实施方案中，然后将顶面22放在中空结构元件20上并焊接，以便通道34完全封闭。随着机动车移动通过油漆烘箱，树脂基增强/粘结材料36热发泡形成坚固的树脂体58，如上所述，其将增强元件32固定在通道34上。换句话说，一旦发泡并完全固化，增强元件32，树脂体58和对立的壁24和26就形成一个显著地增加增强的结构元件18的材料物质的总体。虽然取决于所选择的用来形成树脂基增强/粘结材料36的材料，时间和温度会有很大的变化，但对于前面的表中所提出的优选配方，应该根据促进剂，固化剂和总体的量，将材料36  热到到足够高的温度。
增强的结构18相对于以前的技术中的结构具有许多的优点。通过在受力点战略性地放置增强元件32，可以减少金属疲劳和开裂而不需要使用厚度大的金属板材来形成结构元件20。因此，优选是托架32所占的体积少于结构20即空腔34体积的一半。也最好是托架33的优选构型导致形成一系列(在优选的W-形设计中是三个)的在内壁24和26间延伸的U-形或柱形结构。销钉沿穿过内壁24和26的轴的方向从而沿柱长度方向的耐压力和耐扭办性能是显著的。
值得提倡的是托架33起着树脂体58的容器的作用而防止树脂体58突出，开裂和脱皮，同时还作为一种固定装置。尤其重要的是树脂体58是主要的承载单元。同时，树脂体58使托架33稳定化，以便托架33在树脂体33作为支撑结构之前不弯曲。
在这里说明和描述本发明的一个特殊实施方案时，可以理解的是本发明并不是对其加以限制，因为可以根据这里所公开的内容进行许多的改进，尤其是对于熟悉本领域的人。因此本发明覆盖了属于本发明的精神和范围之内的任何改进。

Claims (22)

1.一种增强的结构元件，包括：
确定一个空间的结构元件；
放置在所说空间中的增强元件，所说的增强元件中有一个托架部分和一个热发泡部分，其中所说的托架部分是所说的热发泡部分的一个容器，并且所说的热发泡部分与所说的结构元件和所说的托架部分相粘结；以及将所说的增强元件固定在所说的结构元件上的装置。
2.权利要求1中所述的发明，其中所说的托架部分中至少有一个孔，以便所说的热发泡部分由该孔扩展，所说的热发泡部分的扩展部分与所说的结构元件相粘结。
3.权利要求1中所述的发明，其中所说的托架部分确定了一个槽，并且其中所说的固定装置包括一个与所说的结构元件相粘结并凸出到所说的空间的凸出部位，所说的凸出部分至少是部分放置在所说的槽中以便将所说的增强元件固定在所说的空间。
4.权利要求1中所述的发明，其中所说的热发泡部分是一种树脂基材料。
5.权利要求1中所述的发明，其中所说的结构元件是一个金属横梁部件，所说的托架部分含有一种同时确定一个槽和至少一个容器的几何形状，所说的热发泡部分是一种放置在所说的容器中的树脂基材料，所说的固定装置是一个延伸进入所说的空间并与所说的结构元件相粘结的凸出部分，所说的凸出部分延伸进入所说的槽中以便将所说的结构元件固定在所说的空间中。
6.权利要求5中所述的发明，其中所说的托架部分是一个含两个容器部分的W-形金属片，所说的容器部分中的一个被放置在所说的槽的一边，所说的容器部分中的另一个被放置在所说的槽的另一边，所说的热发泡部分放置在两个容器内。
7.权利要求5中所述的发明，其中所说的W-形金属片有一个纵向的轴，该纵向轴同时穿过所说的容器和与所说的纵向轴垂直的横轴，其中所说的槽是一个沿所说的横轴延伸的通道，所说的结构元件有相对的侧壁，并且所说的W-形金属片被放置在所说的空间中，让所说的横轴从所说的相对的侧壁之一延伸到所说的另一相对侧壁。
8.一种增强的结构元件，包括：
一个含有相对侧壁并确定一个纵向通道的钢横梁，所说的纵向通道沿一条纵向轴放置；
一个确定空腔的并放置在所说的通道中的由金属制备的树脂支撑增强元件，所说的树脂支撑增强元件至少有一个柱形结构和至少一个槽，所说的柱形结构有一条沿柱形结构的长度方向的柱轴，所说的柱轴在与所说的纵向轴垂直的相对侧壁之间延伸；
一根与所说的钢横梁粘结且延伸进入所说的槽中的销钉；
一个放置在一个由所说的确定空腔的树脂支撑增强元件所确定的空腔中的树脂基芯，所说的树脂基芯被粘结到所说的侧壁和所说的确定空腔的树脂支撑增强元件上。
9.权利要求8中所述的发明，其中所说的树脂基芯由热发泡的树脂基材料所形成。
10.权利要求8中所述的发明，其中所说的确定空腔的树脂支撑增强元件具有一种确定三个柱形结构的W-形构型。
11.一种用来增强一个中空结构元件的增强插件，所说的插件包括：
一个确定一个容纳树脂的空腔和一个容纳销钉的槽的金属托架部分；及
一个放置在所说的容纳树脂的空腔中的树脂基部分，所说的树脂基部分并未完全发泡和完全固化。
12.权利要求11中所述的发明，其中所说的金属托架部分具有W的形状。
13.一种增强的结构元件，包括：
一个确定一个空间的结构元件；
一个放置在所说的空间中的增强元件，所说的增强元件必不可少地含一种与所说的结构元件相粘结的热发泡的树脂基体，所说的树脂基体进一步确定一个槽；及将所说的增强元件固定在所说的结构元件上的装置，所说的固定装置包括插入所说的槽中的装置。
14.权利要求13中所述的发明，其中所说的固定装置是一根被固定在所说的结构元件上的销钉。
15.一种增强结构元件的方法，其步骤包括：
形成一个金属托架，所说的金属托架确定一个容纳树脂的空腔和一条槽；
将一种可发泡的树脂基材料施用于所说的托架中的所说的容纳树脂的空腔中；
提供一个有一个纵向空腔的中空结构元件并在所说的空腔中将一根销钉固定在所说的中空结构元件上；
将所说的含所说的树脂基材料的金属托架放置在所说的空腔中，让所说的销钉穿过所说的槽；及
将所说的树脂基材料发泡以便将所说的托架粘结到所说的结构元件上。
16.权利要求15中所述的发明，其中所说的可发泡的树脂基材料是热发泡的，其中所说的发泡步骤通过加热所说的结构元件来进行。
17.一种增强的机动车横梁，包括：
一个含有确定一个纵向通道的相对侧壁的中空横梁部分；
一根一端与一个所说的相对侧壁相连而另一端与另一个所说的相对侧壁相连的销钉；
一块确定两个容器和一条槽的W-形金属片；
一个在所说的容器中与所说的W-形金属托架粘结的热发泡树脂基芯；
所说的W-形金属片被放置在所说的中空横梁部件的所说的相对侧壁之间并由所说的树脂基芯与所说的侧壁相粘结；及
所说的销钉被放置在所说的槽中。
18.权利要求17中所述的发明，其中所说的横梁有一个连接所说的相对侧壁的底壁且所说的W-形金属片至少有一个孔隙让所说的树脂基芯的一部分延伸穿过，所说的芯的延伸部分与所说的底相粘结。
19.权利要求1中所述的发明，其中所说的发泡部分含环氧树脂，弹性体，煅制二氧化硅，高强度玻璃微球，发泡剂和固化剂。
20.权利要求19中所述的发明，进一步包括填料和促进剂。
21.一种增强结构元件的组合物，包括：
环氧树脂
弹性体
煅制二氧化硅
高强度玻璃微球
发泡剂；和
固化剂
22.权利要求21中所述的发明，其中所说的弹性体是丙烯腈-丁二烯橡胶。
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PL324907A1 (en) 1998-06-22
US20030235675A1 (en) 2003-12-25
US5755486A (en) 1998-05-26
BR9609162A (pt) 2000-05-09
AU711241B2 (en) 1999-10-07
US6863957B2 (en) 2005-03-08
WO1996037400A1 (en) 1996-11-28
EP0827473B1 (en) 2003-01-08
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EP0827473A1 (en) 1998-03-11
ES2188756T3 (es) 2003-07-01
MX9708888A (es) 1998-03-31
JPH11505777A (ja) 1999-05-25
CN1081566C (zh) 2002-03-27
EP0827473A4 (en) 2000-03-29
AU5750596A (en) 1996-12-11
PL182065B1 (pl) 2001-10-31
SI9620084A (sl) 1998-06-30
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CA2221126A1 (en) 1996-11-28
HUP9900371A2 (hu) 1999-05-28
SK157397A3 (en) 1998-06-03

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