CN1206084A - laminate structural bulkhead - Google Patents

Abstract

A hollow reinforced structural member has a bulkhead having a layer of thermally expanded resin disposed between opposed side walls. A sleeve is retained within the resin layer and is oriented perpendicular to the longitudinal axis of the reinforce structural member. The sleeve is an alignment with bolt holes in opposite sides of the reinforced structure such that a bolt can be inserted there through. A component can then be bolted to the reinforced structural member at the site of the reinforcement. The invention not only increases the strength of the part, but also reduces vibration and noise transmission.

Description

The next door of layered structure

The application is based on the provisional application sequence number No.60/053118 that on July 18th, 1997 proposed.

The special box section spare of using in Motor Vehicle is main car frame longeron (rail) for example, and sizable stress will be born in the place of being fixed in longeron at crossbeam.For example when engine stand is fixed on the main car frame longeron, will produce tie point between them, these tie points are easy to break because of tired in time course.In addition, may be with the bolt of this parts fix in position owing to unclamping in the vibration at contact place.And conventional structure can form " noise road ", and this noise road stretches into railway carriage through vehicle frame from wheel and motor.

Understandable as the technician, for very heavy parts are fixed by bolts to longeron side partly, must form one in the bolt position and strengthen zone or supporting structure.Used a kind of method is the punching press next door that a supporting metal sleeve is set in prior art.This next door generally has the flange that three points are welded in longeron C shape part.Specifically be, the next door of punching press has a wall section, and this wall section reaches relative wall or cover plate from a wall of longeron part.Therefore the next door constitutes a dividing plate in groove that longeron constitutes or chamber.For with this wall section fix in position, this next door has three surface or flanges perpendicular to the next door part, and promptly the next door is a shallow rectangular box at a side opening in essence.These three surfaces combine with the longeron internal surface, and spot welding is in place.

For utilizing the fix supporting member of the cross member on this next door of next door, this next door is designed to dispose a metal sleeve, and this metal sleeve is by on the spot welding next door stamping part.Then bolt is passed sleeve, and cross member is fixed on the enhancing zone, next door of longeron.This conventional method below will be with scheming explanation.

Although the design of conventional next door can strengthen the longeron part in the fixed position of cross member really, the sleeve and the stamping part of big mouthful of bore of its fitness for purpose, in fact this increased unwanted vibration and noise.In addition, through bolt, sleeve, metallic stamping pieces and longeron part are basically with discrete parts operation, rather than a single overall enhanced member.This not only causes the increase of above-mentioned vibration and noise, but also longeron is strengthened fully, and causing tie point specifically is the metal fatigue of soldering point.

The inventor has proposed many methods and has for example strengthened the hollow metal parts: the strengthened beam of car door, and it comprises the flute profile metalwork of an opening, this metalwork has and is full of thermosetting property or thermoplastic resin-based material; Hollow torque rod is cut into certain-length, inserts resin-based materials; The precasting of structural member strengthens plug-in unit, and this plug-in unit is made up of many particles that comprise thermosetting resin and foaming agent, this precast piece is expanded in structural member and solidifies in place; The composite door beam, this beam has resin-based core, and this core is no more than 1/3rd of metal die; Hollow layering beam is characterized in that rigid mass than higher, and has outer part, and this outer part is separated with interior pipe by the structural foam of thin layer; I-beam buildup piece, this buildup piece comprise preformed configuration plug with outer foam, and this plug-in unit inserts hollow structural component then; The support of the W shape of metal, this support are as the carriage of expandable resin, and this resin is in place in the hollow parts foaming.

But these have the routine that does not have a kind of method specifically to be used to solve on the landscape orientation element link position with the longeron part in the method to strengthen the relevant problem in next door earlier.The present invention solves problem intrinsic in a lot of prior arts.

The hollow metal member that the purpose of this invention is to provide a kind of enhancing, this member make sleeve and stamping part be combined into the next door member, and the mode of combination is to make the parts in next door form an integral unit with being enhanced member.

Another object of the present invention provides a kind of metal box tee section spare that is enhanced, and makes this box section spare have bigger intensity and don't the remarkable conveying capacity that increases vibration and noise.

A further object of the present invention provides a kind of longitudinal beam part that is enhanced, and with fixed lateral parts engine stand for example, makes stress distribution on the longeron zone that strengthens rather than be distributed on the discrete soldering point, and can cushion noise and vibration.

By the detailed description of the preferred embodiment of the present invention and accompanying drawing, can understand these and other purpose and advantage of the present invention more fully.

In one aspect, the invention provides a kind of member that is enhanced.This reinforcement comprises hollow structural member and the buildup piece that is configured in the structural member.Buildup piece has a pair of relative wall.Dispose the polymer that one deck has added thermal expansion between this a pair of relative wall, this polymer bonding is on this relative wall.This strata compound also directly is bonded on the structural member.A sleeve pipe extends through polymer, and this conduit is parallel to relative wall, and between relative wall.Polymer bonding is on this sleeve pipe, and this sleeve pipe forms the passage by polymer.Be enhanced member and have hole with the end part aligning of sleeve pipe.With bolt parts are fixed on the structural member then.Therefore can utilize buildup piece to strengthen hollow structural component in this position partly in the present invention.Heat whole member and can make the swelling polymer location after assembling, wherein polymer is full of the gap between reinforcement and the structural member through expansion, and reinforcement is bonded on the structural member.

On the other hand, the member that is enhanced of the present invention is for example anterior longeron of automobile longitudinal girder, wherein needs local the enhancing, with fixed component engine stand for example.At this on the one hand, the present invention has reduced vibration and noise transmits, and has increased simultaneously in that part of intensity that strengthens the position.

In yet another aspect, sleeve pipe is a thin-walled metal sleeve, and relative wall is a metallic stamping pieces, and this stamping part has the flange that is welded on the structural member, and polymer is the epoxy resin that has added thermal expansion, and this resin comprises tiny balloon, so that reduce density.

Aspect another, the invention provides the method that a kind of enhancing has the structural member of cannelure.At this on the one hand, the layering member has two can add the relative wall that the polymer of thermal expansion separates by one deck, and this layering member is configured in the groove of longeron part etc.This layering member has and is configured in this layer and can adds sleeve pipe in the thermal expansion polymer layer.This conduit forms the passage perpendicular to this relative wall.This layering member also has the pair of end portions flange.This layering member is placed in the cannelure, makes above-mentioned sleeve channel perpendicular to cannelure.By flange the layering member is welded on the structural member then.Then whole member is heated to the temperature that polymer foaming agent is activated, thereby makes the polymer thermal expansion, make polymer that the layering member is adhered to structural member.

Fig. 1 is the schematic exploded perspective view of conventional prior art next door reinforcement;

Fig. 2 is the schematic front view of Fig. 1 member, and its cover plate is removed;

Fig. 3 is of the present invention to be enhanced the schematic exploded perspective view of longeron part, and the structure in the layering next door of enhancing is shown;

Fig. 4 is the schematic front view of member shown in Figure 3, and its cover plate is removed;

Fig. 5 is the diagrammatic rear view of the next door part of Fig. 3 and 4.

With reference now to Fig. 1 and Fig. 2 of accompanying drawing,, the anterior longeron part 20 of prior art has C shape part 22, and this part forms groove 23 and receives cover plate 24.Dividing plate stamping part 26 has vertical wall 28 and flange 30.Sleeve 32 is welded on the arc-shaped bend part 33 of wall 28.Bolt 36 passes the vertical wall 37 of cover plate 24, sleeve 32 and part 22, passes the parts 38 of waiting to be fixed in longeron 20 then.Subsequently with nut screwing clamping in bolt 36, make parts 38 fix in position.This is the representative of prior art, and has above-mentioned shortcoming, promptly has the not good enough problem that weakens that strengthens insufficient and noise and vibration.

Forward Fig. 3 of accompanying drawing below to, be enhanced the embodiment who is enhanced anterior longeron that member 50 is automobile frames shown in the figure, it comprises the C shape part 52 of longitudinal beam, and this part is made to form groove or chamber 56 in being enhanced member 50 by cover plate 54 sealings.In other words, longitudinal beam is hollow.C shape part 52 comprises vertical wall segments 58 and relative wall section 60,62.Each relative wall section 60,62 has flange part 64, and methods such as utilization welding can be fixed on flange region with cover plate 54.Buildup piece or next door 68 are configured in the groove 56 of C shape part 52, and have first wall or sidewall 70 and second wall or sidewall 72. Wall 70,72 is parallel to each other, and by polymeric layer 74 separately, promptly polymeric layer 74 is configured between wall 70 and 72.

As the Figure 4 and 5 of accompanying drawing are clear illustrate, each wall 70,72 have relevant curved portion (on wall 72 76, on wall 70 78), this curved portion is designed to admit sleeve 81, its mode below will describe in detail.Each curved portion 76,78 is positioned at the centre of the length of each wall 70,72 approximately, and can see curved inner surface as.Sleeve pipe 81 is sleeves of metal etc., and is welded on wall 70 and 72 soldering point 83 and 85, as clear the illustrating of Fig. 4 of accompanying drawing.Polymeric layer 74 surrounds sleeve pipe 81 basically, as shown in Figure 4.

Next door 68 is secured in place in the groove 56 by mounting flange 80 and 82, and this flange 80 and 82 is from wall 70 and 90 ° of extensions of 72 deflections.Each end that is each wall 70,72 has curved section, and this curved section matches with same curved section on the relative wall, forms the adpting flange 80,82 that is welded on respectively on the sidewall 60,62.

The width of wall 70,72 (distance between vertical wall 58 and the cover plate 54) is to make next door 68 contact with vertical wall 58 and cover plate 54.Bolt 84 passes the corresponding aperture (not shown) on hole 66, sleeve pipe 81 and the vertical wall 58 on the cover plate 54.Make bolt pass for example hole on the engine stand 86 of landscape orientation element then, this engine stand is represented by dotted lines in the drawings and is fragment 86.Then nut 86 is screwed on the bolt 84, is enhanced part 56 thereby engine stand 86 is fixed in.

Next door 68 is the quite light member of weight for the intensive quantity that increases on longitudinal beam.Wall 70 and 72 can be made of thin steel pressing, and the thickness of steel for example is 0.02～0.08 inch.Specifically be that low carbon steel is best to the steel of moderate strength.Sleeve pipe 81 is metal sleeve preferably, and its wall thickness is 0.08～0.2 inch a thin-walled, and the most handy low carbon steel is made.Certainly these sizes only are exemplary, are not intended to be limited in the of the present invention complete scope of determining in claims.Each adpting flange 80,82 generally is about 15%～30% of wall 70,72 length.The outer diameter of sleeve pipe 81 is generally about 1/2～1 inch.The width of polymeric layer 74 is functions of distance between wall or plate 70 and 72, generally is about 0.1～0.4 inch.The entire depth that should be understood that next door 68 is full of polymeric layer 74 fully, i.e. shown in Figure 5 as accompanying drawing, and 68 front portion extends to the rear portion to polymeric layer from the next door.

The polymer that is used for forming polymeric layer 74 is the resin-based materials that can add thermal expansion.The present invention can use many resin base mixture and form the layer 74 that adds thermal expansion.Preferred mixture will provide fabulous strength and stiffness characteristic, and weight has only slightly simultaneously increases.Specify layer 74 composition now, for reducing weight as far as possible, the density of material preferably should be in about 20～50 pounds/foot 3 scope.The temperature of fusing point, heat distortion temperture and generation chemolysis also must be enough high, makes layer 74 to keep its structure under the high temperature of the common operation in the devices such as baking vanish case.Therefore layer 74 should bear and surpass 320 temperature, preferably can bear 350 temperature at short notice.In addition, layer 74 should bear about 90～200 long heating and can not show and significantly be subjected to thermal deformation or decomposition.

Foam 74 can be coated in earlier on one or two wall 70,72, expand into then with two walls closely to contact with sleeve pipe 81.When needs add thermal expansion, preferably utilize the heat of baking vanish case that foam 74 is expanded.

More particularly, in a particularly preferred embodiment, the structural foam that adds thermal expansion of layer 74 comprises that synthetic resin, air bag form agent and filler.Synthetic resin accounts for the about 40%～80% of layer 74 weight, more preferably accounts for 45%～75%, preferably accounts for 50%～70%.Resin partly preferably includes flexible-epoxy.According to the application of this paper, term " air bag formation agent " generally is meant the material that produces bubble, hole or chamber in layer 74.Promptly layer 74 has porous structure, and many steam bubbles distribute in its whole polymer blocks.This porous structure forms the material of low-density and high-strength, yet it can form very strong lightweight member.Being suitable for air bag of the present invention forms agent and comprises that " hollow " microballoon of enhancing maybe can make microvesicle with glass or plastics.In addition, air bag forms agent can comprise foaming agent, and this foaming agent can be chemical blowing agent or physics foaming agent.Glass microsphere is particularly preferred.It accounts for the about 10%～50% of layer 74 constouctional material weight, more preferably accounts for 15%～45%, preferably accounts for 20%～40%.When air bag formed agent and comprises foaming agent, this formation agent accounted for weight about 0.5%～5.0% of the structural foam layer 74 that adds thermal expansion, more preferably accounts for 1.0%～4.0%, preferably accounts for 1%～2%.The filler that is fit to comprises glass or plastic microsphere, fumed silica, calcium carbonate, the glass fibre of grinding and the glass yarn of chopping.Thixotropic filler is best.Other material also is suitable for.Filler accounts for the about 1%～15% of layer 74 weight, more preferably accounts for 2%～10%, preferably accounts for 3%～8%.

The used preferred synthetic resin of the present invention comprises thermosetting resin for example epoxy resin, vinyl ester resin, thermosetting polyester resin and urethane resin.Be not intended to make scope of the present invention to be subjected to the molecular resin quantitative limitation, and be appreciated that suitable weight according to the explanation professional and technical personnel of this paper.When the resinous principle of liquid filler is thermosetting resin, can also comprise various accelerants for example imidazoles (imidizoles) and curing agent, be preferably two cyanogen connection acyl ammonia (dicyandiamide), to improve curing rate.The amount that works of accelerant is carried out corresponding conversion by a kind of composition resin in three kinds of compositions, air bag formation agent or filler, generally accounts for 0.5%～2.0% of weight resin.Equally, the amount of curing agent is carried out corresponding conversion according to a kind of composition resin in three kinds of compositions, air bag formation agent or filler, generally accounts for 1%～8% of weight resin.This layer can also comprise processing acid, stabilizer, pigment, ultraviolet absorber of effective amount etc.Thermoplastic material also is suitable for.

In following table, list the optimization formula of layer 74.Have been found that this cooperation side provides a kind of material, this material can complete expansion, solidifies under about 320 temperature, and has fabulous structural characteristics.Except as otherwise noted, all percentages of indication are percetage by weight in this table. composition percetage by weight EPON 828 (epoxy resin) 37.0DER 331 (flexible-epoxy) 18.0DI-CY (two cyanogen connection acid amides (dicyandiamide) curing agent) 4.0IMIDIZOLE (accelerator) 0.8FUMED SILICA (thixotropic filler) 1.1GELOGEN AZ199 (azo dicarbonamide foaming agent) 1.283 MICROS (glass microsphere) 37.0WINNOFIL CALCIUM CARBONATE (CaCO3 filler) 0.9

Although mainly be the present invention to be described, should be understood that the present invention may be embodied as other products for example aircraft, boats and ships, bicycle or in fact need the parts of any device that energy moves at automobile component.Equally, the present invention can also be used with fixing or static structure example such as building, so that provide rigid support when bearing vibration for example by seimic vibration, or simply the member that bears load is formed a lightweight supporting member.In addition, although be primarily aimed at the foam that can add thermal expansion and at metal parts for example in pipe 16,58 and 76 the present invention has been described, can use other material.For example, foam can be any suitable known expandable foam, and this foam can cause the structural foam that expands and form rigidity with chemical method. Next door 70,70 and sleeve pipe 81 can be with the material that is not metal, for example various plastics or polymer materials, or the various lignocellulosic material with enough rigidity that can play backing effect or supporting role to foam.When using when can add the foam of thermal expansion, the heat that next door and sleeve pipe should bear during being heating and curing to be run into.Yet when using the foamed material of other type, next door and sleeve pipe are not necessarily wanted to bear high temperature.At this moment, it is that it should have sufficient rigidity that the basic demand of counter septum and sleeve pipe replaces, so that work in the intended manner.For example, can also be applied in solidify or further handle after itself just become rigidity material make the material of next door and sleeve pipe.When adopting when not being the made next door of metal and sleeve pipe, the present invention also is practical.Yet preferably select material like this, make thin unexpanded foam when expanding, be adhered to next door and sleeve pipe securely, thereby form composite structure.

Although illustrate and illustrate the particular embodiment of the present invention in the text, should be understood that to the invention is not restricted to these embodiments, because particularly the professional and technical personnel can carry out many changes according to content disclosed herein.Therefore, it should be noted that appended claims can comprise that all belong to these changes in the spirit and scope of the invention.

Claims (24)

1. one kind is enhanced member, comprises structural member that forms a space and the buildup piece that is configured in the above-mentioned space, and above-mentioned buildup piece has: the first and second relative walls; The polymer that one deck has expanded is configured between the above-mentioned first and second relative walls and is bonded on this relative wall, and the above-mentioned polymer that has expanded also is bonded on the said structure spare; Pass the sleeve pipe of above-mentioned expanded polymer, above-mentioned ferrule configuration is between the above-mentioned first and second relative walls, and the above-mentioned polymer bonding that has expanded is on above-mentioned sleeve pipe; Above-mentioned sleeve pipe forms the passage that is suitable for receiving bolt.

2. the member that is enhanced as claimed in claim 1 also comprises bolt, and this bolt extends through said structure spare and above-mentioned sleeve pipe.

3. the member that is enhanced as claimed in claim 1 is characterized in that, above-mentionedly is enhanced the longeron part that member is an automobile.

4. the member that is enhanced as claimed in claim 3 is characterized in that above-mentioned automobile longitudinal girder partly is anterior longeron.

5. the member that is enhanced as claimed in claim 4 is characterized in that above-mentioned longeron partly is a U-shaped, has outwardly directed flange, and a cover plate is fixed on the above-mentioned flange.

6. the member that is enhanced as claimed in claim 1 is characterized in that above-mentioned relative wall is welded on the said structure spare.

7. the member that is enhanced as claimed in claim 1 is characterized in that, above-mentioned Socket welding is connected at least one wall in above-mentioned first and second walls.

8. the member that is enhanced as claimed in claim 1 is characterized in that, the above-mentioned structural member that is enhanced has a pair of through hole that aligns with the above-mentioned bolt receive path of above-mentioned sleeve pipe.

9. the member that is enhanced as claimed in claim 1 is characterized in that the polymeric layer of above-mentioned expansion is an epoxy resin.

10. the member that is enhanced as claimed in claim 1 is characterized in that, above-mentioned sleeve pipe is arranged essentially parallel to the above-mentioned first and second relative walls.

11. the member that is enhanced as claimed in claim 1 is characterized in that the polymeric layer of above-mentioned expansion can add thermal expansion, it is made of the material of following percetage by weight: about 40%～60% resin; About 10%～50% microballoon; About 0.5%～5% foaming agent; About 1%～15% filler; About 0.5%～2.0% accelerant; With about 1%～8% curing agent.

12. a structural member that is enhanced comprises: have the longeron of opposing sidewalls and formation cannelure, above-mentioned cannelure is axle along the longitudinal; Be configured in the above-mentioned groove buildup piece perpendicular to the layering of above-mentioned cannelure, the buildup piece of above-mentioned layering has the fixed wall that two relative polymer that expanded by one deck separate; Be configured in the sleeve pipe between the above-mentioned relative fixed wall, this conduit forms a passage; The above-mentioned polymeric layer that has expanded is bonded on the relative wall of above-mentioned longeron and on the above-mentioned sleeve pipe; Extend through the bolt of above-mentioned longeron and above-mentioned sleeve pipe.

13. the structural member that is enhanced as claimed in claim 12 is characterized in that above-mentioned longeron is done with steel, above-mentioned wall has the flange that is welded on the above-mentioned steel longeron.

14. the structural member that is enhanced as claimed in claim 12 is characterized in that, the above-mentioned wall that is relatively fixed comprises an inner nonreentrant surface respectively in the position of above-mentioned sleeve pipe.

15. the structural member that is enhanced as claimed in claim 12 is characterized in that, above-mentioned Socket welding is connected at least one wall in the above-mentioned relative wall.

16. the structural member that is enhanced as claimed in claim 12 is characterized in that the polymer that above-mentioned one deck has expanded is an epoxy resin.

17. the structural member that is enhanced as claimed in claim 16 is characterized in that above-mentioned epoxy resin can add thermal expansion, this resin also comprises the microballoon that reduces above-mentioned epoxy resin density.

18. the structural member that is enhanced as claimed in claim 12 is characterized in that, the buildup piece of above-mentioned layering has flange part in its each end.

19. a method that strengthens structural member, this structural member has the cannelure of connection, and this method may further comprise the steps: a member that has formed a cannelure is provided; Form the member of layering, this member has two relative walls that separated by one deck expandable polymer; Above-mentioned layering member has the sleeve pipe that is configured in the above-mentioned expandable polymer layer, and above-mentioned sleeve pipe forms passage between above-mentioned relative wall; Above-mentioned layering member is placed in the cannelure, makes above-mentioned sleeve channel be substantially perpendicular to above-mentioned cannelure; Above-mentioned layering member is welded on the said structure spare; Activate above-mentioned polymer, it is expand into above-mentioned wall closely contact with above-mentioned sleeve pipe.

20. method as claimed in claim 19, it is characterized in that this polymer can add thermal expansion, and heating said structure spare, the temperature that the polymeric layer that being heated to is enough to make above-mentioned heat-swellable expands, thus above-mentioned polymer is bonded to above-mentioned layering member on the above-mentioned member.

21. method as claimed in claim 19 is characterized in that, said structure spare is an automobile longitudinal girder.

22. method as claimed in claim 20 is characterized in that, above-mentioned epoxy resin also comprises the microballoon that reduces above-mentioned epoxy resin density.

23. structural member that is enhanced that utilizes the described method formation of claim 19.

24. one kind is enhanced structural member, comprises the structural member that forms a space; With the buildup piece that is configured in the above-mentioned space, above-mentioned buildup piece has: the first and second relative walls; One deck is configured between the above-mentioned first and second relative walls and is bonded in the polymer of the added thermal expansion on this wall, and the above-mentioned polymer that adds thermal expansion also is bonded on the said structure spare; The polymer that above-mentioned one deck can add thermal expansion comprises the material of following percent by weight: 37% epoxy resin; 18% flexible-epoxy; 4% pair of cyanogen connection acid amides (dicyandiamide) curing agent; 0.8% imidazoles (imidizole) accelerant; 1.1% fumed silica; 1.2% azo dicarbonamide foaming agent; 37% glass microsphere; With 0.9% calcium carbonate; Sleeve pipe passes the above-mentioned polymer that adds thermal expansion, and above-mentioned ferrule configuration is between the above-mentioned first and second relative walls, and the above-mentioned polymer bonding of thermal expansion that adds is on above-mentioned sleeve pipe; Above-mentioned sleeve pipe forms the passage that is suitable for receiving a bolt.

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