CN1608014A - Automotive rail/frame energy management system - Google Patents

Abstract

An energy management system and device (10) for use in an automotive frame, rail, or other structural component of an automotive vehicle. The frame or rail (16) having a cavity or exposed surface capable of supporting at least one member. The member (12) having an interior portion and an exterior portion with the interior portion being defined by at least one trigger or step change (20) to the geometry of the inner portion to target and direct axial bending of the system. An expandable material (14), such as a polymer-based foamable material, is disposed along the exterior portion of a member prior to final assembly of the vehicle by the vehicle manufacturer. The system is activated as the vehicle undergoes the final vehicle assembly process and paint operation which activates and transforms the expandable material to expand, bond and structurally adhere the frame rail to mange, direct, and/or absorb energy in the event of an impact to the vehicle an applied load or an external force.

Description

Has the special-purpose absorbent automobile composite structural element that impacts

Background of invention

For many years, transit industry all relates to the framing member that design does not significantly increase vehicle weight.Simultaneously, various automobile application requirements framing members partly provide reinforcement can for the target of automobile, and can pass in and out passenger carriage when the contingency collision.Although some devices of being found in the prior art may be favourable in some cases, but the method for prior art normally requires in supplier's equipment, trial production builder pressing equipment or in the end uses additional Fabrication procedure and step in the car assembling planetary wheel, and above-mentioned situation has usually increased labour power needs, period, initial cost and/or required maintenance and cleaned.Therefore, need a kind of simple, low-cost configuration or be used to strengthen the system of automobile longitudinal girder, as a kind of fwd longeron or frame member, said system is strengthened automobile and is controlled distortion in any collision, the additional strengthening globality, and can be included in effectively in the Automobile manufacturing process.In addition, also need a kind of system or structure of lower cost, said system or structure provide reinforcement, and prevent the distortion of vehicle frame in the automobile or front rail structure, and can be used for managing front/off normal and impact energy on the automobile by strengthening frame member or front rail, so that help the added load of aiming, and the energy management of help change of direction or adjusting distortion.

The needs that the vehicle structure selectivity is strengthened have been increased in addition, so that controlled deformation and/or satisfy various government test standards.For this reason, study some structural foam and carriage, be used for strengthening the purpose of automobile ad-hoc location.The principal focal point of these reinforcements is to gain in strength and rigidity to a kind of structure.

Just as the skilled artisan will appreciate, in estimating reinforcement efficient 3 factors of general significance be rigidity, weight and cost.Under most prior art production technology situation, increase rigidity and cause the cost that corresponding weight increases and cost increases.For example, although utilize the metal of thicker standard specification to gain in strength, it causes undesired weight to increase.Equally, utilize exotic high-strength alloy effective, but this has increased the cost of automobile greatly to gaining in strength.At last, should be appreciated that the cost of resin is also relevant, and therefore structural foam must be saved use.

Another relation when using structural foam is the problem relevant with complete curing very thick material.That is to say that in some prior art was used, some were so thick for strengthening desired material satisfactorily, so that it is difficult to reach complete curing.Therefore, should be appreciated that the technology that is used to strengthen hollow structure does not produce the problem of significant weight or cost or curing aspect, the above-mentioned technology that is used to strengthen hollow structure might provide significant advantage.

Therefore, an object of the present invention is to provide a kind of structure reinforcement, the said structure reinforcement utilizes structural foam in a kind of mode of saving resin.

Another object of the present invention provides a kind of like this reinforcement, described reinforcement can be in a short time complete curing.

Another object of the present invention provides a kind of low cost, lightweight structure reinforcement, and described reinforcement provides sizable strength and stiffness for the zone through strengthening.

It is that the local structure reinforcement is provided in one way that the present invention also has another purpose, causes any impact energy of being out of shape of beginning at least so that be dissipated in any select location place.

The present invention also has another purpose to provide a kind of structure reinforcement, and the said structure reinforcement can be easy to be transported to the place of erection.

Also have a purpose to provide a kind of chipware stiffening structure spare that passes through, above-mentioned chipware joins on the framing member by aforesaid structural foam, and some passages wherein are provided between chipware and framing member, so that allow water flow.

Summary of the invention

The objective of the invention is to make added load change of direction and manage impact energy by in the target area of automobile longitudinal girder or frame member, laying a strengthening system.System generally uses at least one member or plug-in unit, and above-mentioned member or plug-in unit are fixed or are adhered on the selected part of automobile, on the vehicle frame or longeron or any other parts as selected automobile, is out of shape to the vehicle impact incident time so that prevent.One or more members one of them is suitable for accept using a kind of expandable material, one of them part of above-mentioned expandable material covering member outside face at least.Be arranged on expandable material on the member when being exposed to automotive paints operation, as the e application in the automobile assembly plant or other paint run in the cycle pine for the time can activate and expand.Can expect, disclosed in the present invention expandable material activation, expansion and bonding, thereby structurally strengthen and increase the strength and stiffness of vehicle frame or front rail, so that make load and the energy change direction that applies.In one embodiment, material be het expansion and cavity of filling at least in part, described cavity is limited by the selected part of longeron, vehicle frame or automobile, above-mentioned expandable material e coating baking operating period according to structurally bonding longeron of the size and dimension of cavity and vehicle frame.

In another embodiment, but expandable material is a kind of melt expanded material, and above-mentioned expandable material will be dispersed on the surface when hot applying.Selected expandable material can also provide various characteristics, strengthens comprising structure, and stress-strain reduces, damping of vibrations, and noise reduces, or their any combination.

In a preferred embodiment, therefore the present invention provides a kind of structure reinforcement, so that the local reinforcement that comprises a kind of chipware is provided, above-mentioned reinforcement is fixed to one or more structural materials parts on the above-mentioned chipware, reinforcement is equipped with the device that is used for fixing on the member to be strengthened, the device that wherein is used for fixing is like this, so that before foaming, at chipware, provide a passage between structural foam and the inner surface of component to be strengthened, with foaming process structural foam can be expanded, and chipware is joined on the inside face of member to be strengthened.

In a preferred embodiment, structural foam is fixed on the chipware as some band or point.In a further advantageous embodiment, structural foam provides by a certain amount of, so that form a kind of rigid joint between chipware and structure inside face to be strengthened, and keeps an air by-pass passage between chipware and inside face, be used for water flow, above-mentioned moisture may be owing to condensation exists.We are the 20%-45% on structural foam covering chipware surface preferably.

The present invention also is used for managing crash energy, and described crash energy runs in the front of automobile and back impact test process usually.More particularly, member of the present invention or plug-in unit can be located like this, so that its guiding impact energy, and in addition in a preferred embodiment, can comprise at least one and preferably a plurality of drg, above-mentioned drg comprises other form that some breach, hole or any step change, the perhaps variant of one or more interior sections of the variant of member geometric configuration such as member.The position of reinforcement can be like this in the vehicle frame, so that the reinforcement in a zone can deflect into impact energy on another second area, consequently deforms at the second area place.Equally, the inner brake place is being set, they can aim at axial bending and direct on the selected part of system effectively, and can manage the crash energy that runs at positive off normal duration of test usually.

In the reinforcement of automobile longitudinal girder, this is particularly useful, automobile longitudinal girder so solidifies usually, so that the warp architecture wherein big reinforcement of a part can be transferred to energy on the wherein part of structure, wherein a part of less reinforcement of said structure causes to begin distortion at least like that in the zone of minimum reinforcement.This can be used for controlling back or positive distortion when impacting, and guarantees for example in the less distortion in threshold place simultaneously.Strengthening degree change can be by changing the intensity and the thickness of used reinforcement material, standard specification and type as various materials such as steel, in some part, provide the foamed materials reinforcement simultaneously around a chipware, and the foamed materials reinforcement is not provided in other zones, perhaps by finishing with the pre-prepd reinforcement of the non-reinforcement bonded assembly of another location location at one.Have now found that, this is particularly useful when the S shape segmentation of the front of strengthening automobile or rear rail, herein can one general below S shape in the bending with a bigger reinforcement, so that guarantee distortion, have less in another knee of above-mentioned S shape or do not have reinforcement in some cases in course of emergency control of another knee of S shape.

Expandable material is arranged on wherein at least a portion of member, and above-mentioned expandable material can be in a kind of fabricated device such as punching press facility, or in the end during the assembly manipulation, extrusion molding, molded or " miniature coating " join on the member.Member and selected joint or expandable material were installed in before e application or paint operation are handled among the selected vehicle frame or longeron.Therefore, the present invention provides alerting ability in manufacturing process, because it can have been reduced labor content, initial cost, maintenance requirement and floor area requirement simultaneously by vehicle frame or automobile component (front rail) builder/supplier or car maker utilization.In case expandable material engages and is cured on the selected longeron or vehicle frame part of automobile, then, can prevent or manage the distortion of vehicle frame or longeron such as front or rear rail to during the front/any other of off normal impact event applies impact energy of automobile external.By absorbing and/or shifting certain impact energy and reinforcement partly is provided for the vehicle frame or the longeron of automobile, the present invention provides a kind of system that is used to manage distortion in front, off normal or back impact event to automobile.

Brief description

Seeing following detailed description, when claims and accompanying drawing, characteristics more of the present invention and inventive aspect will become more apparent, be each brief description of drawings below:

Fig. 1 is the isometric view that the chassis side rail that the local parts according to the described energy management strengthening system of the technology of the present invention decompose is shown.

Fig. 1 (a) be a kind of strengthening system of usually finding in the prior art wherein a part expose view, this figure describes usually 3 crush zones relevant with frontal energy management structures in the auto-industry, and the use external actuators is shown is arranged on known in this technology member exterior portion.

Fig. 2 be the present invention of in the design of automobile frame construction or body in white, being described wherein a part expose diagrammatic sketch, this illustrates the position of at least one member that has expandable material, and above-mentioned expandable material is on the longeron that its uncured state is fixed to automobile.

Fig. 3 is the part of system shown in Figure 1, this illustrates an alternative embodiment of at least one member band expandable material of the present invention, above-mentioned expandable material was in its uncured state before on vehicle frame that is fixed to automobile or the longeron, and the anchor fitting that the present invention gets a clip assembly form is shown.

Fig. 4 is the part of system shown in Figure 1, and this illustrates an alternative embodiment of at least one member band expandable material of the present invention, and above-mentioned expandable material was in its uncured state before on vehicle frame that is fixed to automobile or the longeron.

Fig. 5 is the part of system shown in Figure 1, and this illustrates an alternative embodiment of at least one member band expandable material of the present invention, and above-mentioned expandable material was in uncured state before on vehicle frame that is fixed to automobile or the longeron.

Fig. 6 is the part of system shown in Figure 1, and this illustrates an alternative embodiment of at least one member band expandable material of the present invention, and above-mentioned expandable material was in uncured state before on vehicle frame that is fixed to automobile or the longeron.

Fig. 7 is an exploded perspective illustration, this illustrates an alternative embodiment who is arranged on the system in a kind of closing form, wherein a plurality of member reciprocal interlockings also pass through one the 3rd member maintenance, above-mentioned the 3rd member also comprises a self-locking mechanism of the present invention and a drg, above-mentioned drg is depicted as a hole, and the interior section of member is run through in described hole.

Fig. 8 illustrates the reinforcement of Fig. 7.

Fig. 9 is the exploded perspective illustration of automobile longitudinal girder strengthening system of the present invention before energy impact, and above-mentioned energy impact runs in the frontal impact test of automobile usually.

Figure 10 is the exploded perspective illustration of automobile longitudinal girder strengthening system of the present invention after energy impact, and above-mentioned energy impact runs in the frontal impact test of automobile usually, and the influence of axial bending to system of the present invention is shown.

The present invention also illustrates by reference accompanying drawing 11 and 12, and wherein Figure 11 illustrates according to a kind of reinforcement of the present invention, and Figure 12 illustrates and is positioned at half in-to-in reinforcement below the longitudinal divisions of automobile front.

Figure 13 is the scheme drawing according to the vehicle front rail of the described reinforcement of one embodiment of the invention.

Figure 14 is the scheme drawing that the system shown in Figure 13 local deformation is shown.

Detailed description of the invention

The present invention relates to be used for management energy and reduce the certain methods and the system of vehicle impact deformation characteristic, especially relate to minimizing to the distortion in automobile front/off normal impact event.More particularly, the present invention relates to a kind of system, described system is used for strengthening, the guiding impact energy, and the management of above-mentioned impact energy is adjusted on the each several part such as vehicle frame or longeron of automobile, said system is implemented to reduce or prevent that the practical distortion of passenger carriage or structure from moving the incident of impacting automobile external from other object.System absorb to dissipate and/or shifts impact energy, so as to reduce and prevent to be produced automobile deformed.The minimizing of vehicle impact distortion can be used for reducing passenger's injury, and permission continuous passenger after impact event passes in and out automobile, and reduces repair time and reduction expense.

Two kinds of main automobile frontal impact test methods of auto-industry general using: complete front and off normal.The frontal impact test is used for two kinds of the United States Federal's performance audits and ranking test fully.Although these tests normally under different speed (that is to performance audit with 30mph (miles per hour) with to ranking test 35mph), they the two relate to a kind of barrier impact that utilizes the whole width of test car front-end architecture.The main purpose of these tests is to estimate passenger's response (femur load, Head Injury Criterion, chest deceleration etc.), and confirms automobile protection system (seatbelt, air bag etc.).The off normal impact test is normally having only 40% of test car front end to impact under the situation of barrier under 40mph to carry out.One of main purpose of off normal impact test is to estimate the structure integrity of vehicle structure itself.

The design that head-on crash can be managed is a kind of multinomial process violating the regulations.Crash energy management is normally implemented by a kind of combination of vehicle structure and protection system.Many car manufacturers all can be designed to endergonic vehicle structure in searching.Structure efficiency depends on the design-calculated structure, and the said structure definitions of efficiency is the ability along with vehicle structure distortion when impacting optimization energy management.For frontal impact test occasion, impact the serious crushing load that is produced by energy management structures and tend to make passenger carriage to slow down.Energy management structures is the ability of manageable load transfer to a passenger carriage; combine with dissipate the effectively ability of these load of protection system; can help to command passenger carriage how fully extreme loads to be responded, and how passenger carriage keep minimum distortion and interference under certain conditions.Owing to these reasons, prior art concentrates at least two main considerations at the vehicle structure design aspect that is used for crash energy management: the absorption of (1) almost car kinetic energy and (2) are for bearing crushing process intrinsic in the process of the test and keeping necessary crash worthiness energy of passenger compartment integrity or intensity.

The traditional frontal energy management structures of automobile generally comprises 3 distinct crumple zones.At first, a soft district is arranged, this soft district is bumper/spoiler district or other exterior fascia normally, above-mentioned soft district two than the hard area after.As defined herein with discuss, two will be referred to as primary area and auxiliary region than the hard area.Main crumple zone is to be positioned at after the soft crumple zone or contiguous above-mentioned soft crumple zone traditionally, as the bumper assembly of automobile, is the front of chamber at automobile power still.Secondary crush zone is normally defined main crumple zone bridge joint or fastens the zone in car occupant compartment.For band vehicle frame formula automobile, as truck and relatively large automobile, secondary crush zone extends to the front truck stature usually, as shown in Figure 1a.For less automobile, vehicle frame can merge in the body in white design.This type design is commonly referred to as the space frame structure in this technology, as shown in Figure 2.Under space frame vehicle structure situation, secondary crush zone extends back, and will lead crashproof damage zone bridge joint simultaneously or is tied on the tread plate zone of automobile fireproof bulkhead and passenger carriage.Because secondary crush zone near the passenger carriage of automobile, so must utilize designing requirement and energy management control technology, reduces to minimum so that may invade passenger carriage.

Therefore, a main purpose of known crumple zone technology in this technology is not damage management maximum energy under the passenger compartment integrity situation.In one embodiment, the present invention illustrates these needs by an energy management system and structure, and above-mentioned energy management system and structure provide one to be used for stable platform or the system that main crumple zone destroys gradually.That is shown in Fig. 8 and 9, the present invention provides stability to secondary crush zone, and above-mentioned auxiliary crashproof damage zone prevents warpage or distortion when main crumple zone is crushed, so that total is scheduled to by one and the mode of management is destroyed gradually.Shown in Fig. 8 and 9, the present invention can comprise a plurality of drgs, so that by forming opposite or the tangent bend pattern implements to turn to destruction.Shown in Figure 10-13, the present invention can not strengthen upper part and forms local failure by the lower part of strengthening front side member.System of the present invention or structure can also be used for managing crash energy by attempting the advocate peace deformation characteristic of secondary crush zone one of them or the two of control by this way, reduce to minimum so that passenger carriage is invaded.

Just as known in the art, energy management structures distortion (destruction) in a kind of combination of axial and bend mode.Many existing energy management system are utilized bend mode, and above-mentioned bend mode produces lower energy management capabilities.For example, because bend mode is less effectively from the viewpoint of energy management,, manage energy with axial collapse design same amount and type so it needs the many designs of recuperation usually or adds competent structure.Weight is that axial manner is preferred energy management method in the great majority design of standard in automobile design and performance.Bend mode comprises local linkwork of formation and linkage type motion, and above-mentioned bend mode also is a kind of lower energy mode.For example, a kind of structure has the trend of a destruction owing to lower energy mode in bend mode.In view of the situation, even also fail to carry out bend mode, unless in design, provide other constructional feature to increase stability and anti-oblique load for the custom-designed a kind of structure of axial collapse.

Axially foldingly also can think actv. energy absorption mechanism.Because potential fugitiveness and lower energy are failed to carry out bend mode, so it also is the most inaccessible.Therefore, in a preferred embodiment, energy management system of the present invention or structure by use the secondary crush zone of advocating peace one of them or the two in design-calculated at least one, preferably a plurality of drgs, searching makes the axial collapse of automobile each several part reach maximum, and makes crooked minimum simultaneously.One or more drg of the present invention is defined as variation or the discountinuity in a part of geometric configuration of the secondary crush zone one of them or the two of advocating peace that forms structure of the present invention, the structure of the invention described above is designed to produce stress riser, so that cause local bending.Preferably utilize a plurality of drgs in the present invention, perhaps different geometries design-calculated drg combination is so that begin to fold in the structure that 3 completely different crumple zones that comprise the frontal energy management structures shown in Fig. 1 and 2 wherein axially destroy at least one the collimation part.When utilizing drg of the present invention, with their sizings and design, the axial collapse that guarantees structure shown in Fig. 1 and 2 can take place under sufficiently high load, so that make energy that structure manages and the energy that runs into usually in the frontal impact test reach maximum.

The drg of recent findings has in the prior art generally been done change to the outside each several part of used metal construction reinforcement or plug-in unit, so that strengthen selected body portion of automobile or cavity such as longeron, pillar, cross member of frame etc., and the zone in any other next-door neighbour's car occupant compartment.The part that these prior art drgs generally include some holes or conform to structure reinforcement or plug-in unit exterior portion shape.Yet, in a preferred embodiment, although the interior section of a structure reinforcement or plug-in unit has been done change, the invention provides at least one, and preferably a plurality of inner drgs supply management energy usefulness, and above-mentioned energy is run at the frontal impact duration of test by automobile usually.When using, inner drg of the present invention makes the axial bending aiming effectively and directs into each selected part of structure, and can comprise that breach, hole or any other form step change or the substitute of structure reinforcement or wherein one or more interior sections of plug-in unit.For example, structure reinforcement of the present invention or plug-in unit are used for multiple purpose, and a kind of method that is used to manage impact energy is provided.At first, member or plug-in unit play a kind of stable device action, and the aforementioned stable device is strengthened secondary crush zone, thereby allow main crumple zone can make axial crushing reach maximum.In case main crumple zone reaches the ability of absorption maximum impact energy, the secondary crush zone of structure of the present invention must be designed to absorb certain additional energy, as a kind of method that reduces the distortion of car occupant compartment.Structure of the present invention is utilized a plurality of drgs, cuts part as a plurality of breach of member or plug-in unit or one, is used for beginning the bending of structure according to its existing geometric configuration.

In one embodiment of the invention, at least one member 12 or plug-in unit are placed in one of them part of automobile chassis frame or longeron, adhere to, fix or adhere on one of them part of above-mentioned automobile chassis frame or longeron, wherein at least one member 12 comprises a kind of material 14 of inflatable or foaming, and the material 14 of above-mentioned inflatable or foaming is by member 12 each several parts supportings or along the each several part setting of member 12.Member 12 has an interior section and an exterior section, and can constitute with Any shape, design or the thickness of the size of selected vehicle frame of corresponding net gas car or longeron, and can comprise a plurality of drgs of incorporating in member 12 interior sections, above-mentioned a plurality of drg design also is mounted to special adjusting or aiming impact energy, be used to absorb or change of direction to the other parts of automobile.Expandable material 14 extends along wherein at least a portion of member 12 exterior portion length, and can filling be limited to the cavity in vehicle frame or the longeron or the wherein at least a portion in space.

System's 10 general at least one member 12 of using, described member 12 is suitable for making structure hardening to be strengthened, as vehicle frame or front or the rear rail of in automobile, being found, and the impact energy that helps management better in automobile front/off normal impact test, to be run into usually.In use, one or more members are arranged in selected vehicle frame or front or the rear rail, perhaps mechanical type adhere to, snap engagement, fixing or stick with glue agent and be adhered on wherein at least a portion of selected vehicle frame or front or rear rail, simultaneously with hot activation formula expandable material as a kind of load transfer energy absorbing medium that is provided with along at least one outside face of member.In one embodiment, one or more members 12 comprise a kind of injection moldable polymers carriage, a kind of injection moldable polymers, graphite, carbon or a kind of molded metal such as aluminium, magnesium or titanium and a kind of alloy or a kind of foamed materials or other metal foaming material that obtains by above-mentioned material that obtains by above-mentioned material, and in its two sides at least on one of them, and be a kind of expandable material 14 of application at least in part on 4 or more sides in some cases.

In addition, can expect, member can comprise a kind of nylon or other polymeric material, as in generally accepted U.S. Patent No. 6,103, described in 341, above-mentioned patent is particularly including in this article as a reference, and injection moulding, extrusion molding, die casting or mach member comprise some materials such as nylon, PBI (polybenzimidazoles) or PEI (polyetherimide).One or more members also can be selected from following material, and these materials comprise extruded aluminium, foamed aluminium, magnesium, various magnesium alloy, molded magnesium alloy, titanium, various titanium alloy, molded titanium alloy, polyurethanes, polyurethane composition, low density solid filler and foam SMC (sheet molding compound) and BMC (bulk moulding compound).Further, be suitable for making the member of structure hardening to be strengthened can comprise the cold rolling copper of the high strength low alloy steel of the cold-rolled steel of a punching press and moulding, a kind of punching press and moulding, a kind of roll forging moulding or a kind of high strength low alloy steel of roll forging moulding.

It is known in this technology that many structures are strengthened foameds materials, and also can be used for producing expandable material of the present invention.The representative type structural foam comprises a kind of polymer-based material, as a kind of epoxy resin or polyvinyl, above-mentioned polymer-based material is worked as and some appropriate ingredients (normally a kind of foaming agent, a kind of curing agent and perhaps be a kind of filler) during chemical combination, expand and curing when heat or other exciting stimulate applying in a kind of reliable and predicable mode usually.The material that produces has lower density and enough rigidity, so that desirable rigidity is given the goods of a supporting.From a kind of chemical standpoint that is used for hot activation formula material, structural foam normally began to be processed into a kind of thermoplastic material before solidifying.After solidifying, structural foam becomes fixing and thermoset material that can not flow usually.

Expandable material generally is a kind of thermoset material, and preferably a kind of hot activation formula epoxy, above-mentioned epoxy has foam characteristics when utilizing heat to activate, and above-mentioned heat runs in a kind of e application or other automotive paints furnace operating usually.When expandable material heats, its expansion, crosslinked, and structurally join on the adjacent surface.An a kind of example of optimization formula is a kind of epoxy-based material, and above-mentioned epoxy-based material can comprise some polymer modifiers, and as a kind of ethylene copolymer or ter-polymers, above-mentioned ethylene copolymer or ter-polymers can be from L ﹠amp; L Products, Inc of Romeo, Michigan buys, and the trade mark is L-5204, L-5206, L-5207, L-5208, L-5209, L-5214 and L-5222.The advantage that the preferred construction foamed materials is better than the prior art material is that above-mentioned preferable material can be processed in several ways.The possible process technology that is used for preferred material comprises the direct decomposition of injection moulding, blow moulding, Heat forming, granulated material, extrusion molding or with miniature spreader extruding machine extrusion molding.This can form some component designs, and above-mentioned component design surpasses the flexible design sexuality of most prior art material.In essence, any have the foamed materials that structure adds powerful feature and can be used in combination with the present invention.The economy of through performance requirement and special applications and requirement is determined in the selection of used expandable material.In general, these automobiles are used can utilize disclosed those technology and processing in the following patent: United States Patent(USP) Nos. 4,922,596,4,978,562,5,124,186 and 5,884,960 reach the total U.S. Patent application No.09/923 that awaits the reply, 138, and the WO 02/14109 of PCT application submission on August 8 calendar year 2001, the WO 01/58471 that submit to January 18 calendar year 2001, the WO 01/68394 that submit to March 1 calendar year 2001, the WO 02/26550 that submit to September 26 calendar year 2001, the WO 02/26551 that submit to September 26 calendar year 2001, the WO02/26549 of September 26 calendar year 2001 issue and especially, the WO 01/41950 of issue on December 7th, 2000, above-mentioned patent all is included in herein as a reference.

Structural foam can be applied on the surface of chipware in any suitable manner, and preferred mode will depend on the character of core material.For example, if chipware is a kind of plastics such as Pyralin and uses injection moulding production that then structural foam can apply by two kinds of injection injection mouldings or overmolding method.

Alternatively, if chipware is the metal of for example producing by pressing, then structural foam can be by fusing process of intermediate or by being coated with a kind of adhesion agent.Do not consider in the alternative plan of chipware character that at another kind structural foam can be with mechanical method fixation to chipware.Some examples of mechanical fixation method comprise as US Patent 6,311, pin described in 452 or groove.A kind of preferred fixing means is to promote, and above-mentioned distribution can pass that formed hole pushes away inward in the chipware, so that hold pin.In this preferred embodiment, saved the special molded and/or adhesive effect of structural foam.

The invention provides a kind of method comes cost-cutting, improvement rigidity and increases to utilize a kind of compound structure to reach the possibility of complete curing structural foam from start to finish.The surface of reinforcement can be fixed with key so that be coated with uncured resin like this, make produce between the uncured resin of member and coating mechanical interlocked.This interlocking can be positioned on the reinforcement resin, and does not need to heat reinforcement, utilizes a kind of second adhesion agent, heats uncured structural foam, or utilizes the uncured foamed materials of a kind of pressure sensitive.If structural foam is fixed on the chipware with promoting, can obtains similar benefit.Except easy to process, the surface push pins fixing with key produces a kind of structure, anti-very doughtily damage the during said structure is handled in shipment or in assembling plant.In one case, the main uncured heat expandable material that is fixed on the reinforcement is not a pressure-sensitive.This can pack like this, so that adjacent preforming parts are at mutually non-adhesive Time of Shipment (that is material does not play the pressure sensitive adhesive effect).

Structure of the present invention can be installed many different choice schemes for advantageous applications of the present invention in the hollow structure part of self-propelled vehicle.A kind of possibility is that the end cap (not shown) is fixed on the additional strengthening.These end caps can have an integral fastener or spring-loaded; So that can install and be positioned in the automobile.Another selection scheme is to form a kind of parts with plan stiffening structure near the net form shape, and it becomes taper when being installed in the hollow cavity with box lunch, and thereby location.This normally needs the vehicle area strengthened, above-mentioned reinforcement is not linear, and comprises that above-mentioned partial cavity covers with another piece sheet metal with in a part of lay to a partial cavity.A kind of additional installation method is to apply a pressure sensitive adhesive on certain surface of compound additional strengthening.Target on reinforcement is decided, and pressure-sensitive adhesive can or also cannot have the behavior of structure after solidifying.

In a preferred embodiment, utilize structure reinforcement of the present invention to increase the front longitudinal divisions of automobile accessory frame.A kind of front longitudinal divisions of type of motor car is a framing member, and said structure spare helps supporting engine, and carries fuel pipes is to driving engine.The front longitudinal divisions of automobile is a kind of box shaped tube of bending normally, and reinforcement is to be assembled in the box shaped tube and the crooked distortion that reduces this segmentation when in the end colliding in this segmentation during the automobile frontal impact.In this embodiment, reinforcement preferably runs through the reinforcement length of being out of shape when mostly not standing head-on crash and extends certain scope at least.Preferably U or D shape of reinforcement in this case, the major length along the component wall part has the structural foam band simultaneously.Alternatively, structural foam can spot weld on the reinforcing core member.

Usually front rail comprises at least two sweeps, and above-mentioned sweep forms S shape sometimes.Usually wish when impacting front rail to begin distortion be to take place in the most close automobile fwd longeron curve office.This can finish by having different reinforcement degree two curve offices, has bigger reinforcement degree away from automobile fwd curve office simultaneously.This can utilize a reinforcement to have different reinforcement abilities two curve offices and finish, this can finish by the material that utilizes varying strength and rigidity, less reinforcement foamed materials is provided for the most close automobile fwd sweep or without any foamed materials.Alternatively, it can not strengthen second sweep and finish by strengthening first sweep.

Resin is as bar regardless of it or point all is expandable usually.That is to say that applying when hot, they will expand, above-mentioned expansion is normally by foamable reaction, and preferably expand into 150% of the volume that is at least unswollen state, and one times of cubic expansion more preferably.In a preferred embodiment, the resin that is used for forming resin streak or point is the epoxy resin sill.

Resin preferably forms the about 75wt% of about 5wt%-of composition, and more preferably about 15wt%-65wt%.Filler preferably forms the about 70wt% of about 0wt%-of composition, and the about 50wt% of more preferably about 20wt%-.Foaming agent preferably forms the about 10wt% of about 0wt%-of composition, and more preferably about 0.2wt%-5wt%.Curing agent preferably forms the about 10wt% of about 0wt%-of composition, and more preferably about 0.5wt%-5wt%.Accelerant preferably forms the about 10wt% of about 0wt%-of composition, and 0.3wt%-5wt% more preferably.A kind of preferred prescription is shown in the following Table 1.

Composition	Percentage by weight (Wt%)
		Epoxy resin	????15％-65％
Ethylene copolymer	????0％-20％
		Foaming agent	????0.2％-5％
Curing agent	????0.5％-5％
		Accelerant	????0.3％-5％
Filler	????20％-50％

As mentioned above, most preferably a kind of hot activation formula of thermal expansion material, be the epoxy resin sill basically.Yet other suitable material also can be used.These materials comprise polyolefine material class, copolymer analog and have the ter-polymers class of at least a haplotype alpha-olefin, phenolic resin material class, phenoxy group material type, the polyurethane material class with high glass transformation temperature and other material.Generally, the desired characteristic of this thermal expansion material be high rigidity, high strength, high glass transformation temperature, good corrosion resistance, be adhered to the metal of being stained and the ability on the polymer surfaces, when activating, solidify fast, good treatment characteristic, low cured density, low cost, and long life.

The chipware of reinforcement can be any suitable material, and described material has strength/weight balance, so that desirable reinforcement degree is provided under minimum weight.Chipware can be a plastic material, and it can utilize injection moulding or extrusion molding production under the plastics situation.In the place of using plastics, glass-filled polyimide (nylon) is a kind of preferable material.Alternatively, chipware can be a kind of metal, and steel or aluminium are preferred herein.At chipware is can be by the metallo-place of extruding, percussive pressure cast one-tenth, and extruding and impact are preferred.

The invention provides in the preferred embodiment of structure reinforcement in the automobile in utilization, expanded material is such, and promptly it forms foamed materials under a temperature that is higher than used temperature in the anticorrosive finishing (being commonly referred to as the e application).Expanded material preferably activates being used for toasting under the temperature of coating material, and said temperature is generally 149 ℃ or higher, but the trend of utilizing lower temperature is arranged.On the other hand, core material should be like this, and promptly it is not subjected to some conditions that automobile stood in manufacturing process, especially Temperature Influence to a great extent.In a preferred embodiment, utilize the present invention to strengthen the form longitudinal divisions of automobile.In this preferred embodiment, reinforcement should be like this, promptly before foaming, pipeline and metal wool and especially fuel canal can be promoted to pass the longitudinal divisions that comprises reinforcement.Therefore preferably reinforcement is channel shape and does not have the internal protrusion part as rib, and above-mentioned bossing may stop the passage of these metal wools and pipeline.

Utilizable in the present invention other expanded material and expanding material comprise other materials, above-mentioned other materials are suitable for as joint, energy absorbing or acoustic media, and can be hot activation formula foamed materials, above-mentioned hot activation formula foamed materials is when be exposed to the following time of temperature that runs into usually in automatic e application curing oven or other paint operation stove, the general activation also expanded, so that the desirable cavity of filling or occupy desirable space or work.Although other hot activation formula material can be used, but a kind of preferred hot activation material is a polymer formulators inflatable or foaming, and preferably when under the heating operation that is exposed to a representative type auto assembly paint operation, can be activated to a kind of prescription of foaming, mobile, bonding or other variable condition.For example, under limited case not, in one embodiment, the polymer foaming material can comprise a kind of ethylene copolymer or can have a kind of ter-polymers of alpha-olefin.As a kind of copolymer or ter-polymers, poly-mer comprises two or three different monomer, that is has the little molecule of high chemical reactivity, and above-mentioned little molecular energy is with similarly molecule crosslinked.Some particularly preferred examples of polymers comprise ethylene vinyl acetate, EPDM (propylene diene copolymer), or their compound.Under limited case not, the example of the preferred foaming formulation of commercially available other comprises can be from L ﹠amp; L Products, Inc.of Romeo, the polymer-based material that Michigan buys, the above-mentioned polymer-based material trade mark is L-2018, L-2105, L-2100, L-7005, L-7101, L-7102, L-2411, L-2420, L-4141 etc., and can comprise open circuit or closed cell polymer-matrix bottom material.

In addition, can expect that expandable material of the present invention can comprise acoustic attenuation performance, when by heat activation, above-mentioned acoustic attenuation performance also can help to reduce the vibration and the noise of whole vehicle frame, longeron and/or vehicle body.In this respect, vehicle frame or the front rail through reinforcement and vibration damping will increase the rigidity that reduces natural frequency now, and above-mentioned natural frequency passes through car chassis resonance, thereby transmit, stops or the absorption noise by utilizing conjugation sound absorption goods to reduce.By increasing the stiffness and the rigidity of vehicle frame or front rail, can reduce by automobile runs producing and the amplitude and the frequency of whole noise/vibration by the automobile transmission.

Also have in addition, be appreciated that, used reinforcement carriage among the present invention, and the material of the formation geometric form step of in carriage of the present invention or member, finding variation, can comprise a kind of reactivity or non-reactive material, above-mentioned material produces high compression-strength and modulus, and can form carriage or member itself, perhaps can filling or application carriage or member.In general, the material that shows this higher compression intensity and modulus can be selected from one group of material, above-mentioned this group material comprises foamed materials or some low density fillers of a kind of synthesising foam material, synthesis type, as spheroid, hollow ball, Ceramic Balls, comprising their granulations and extruding prescription.In addition, carriage or member can comprise a kind of cement concrete foamed materials, synthesising foam material, foamed aluminium, foamed aluminium ball or other metal foaming material, and their alloy.An example of these materials comprises general known U.S. Provisional Patent Application series No.60/398,411, and " the composite metal foam decay/additional strengthening " submitted to July 25 in 2002, and be included in herein as a reference.Other material that is suitable as carriage among the present invention or member comprises polysulfones, aluminium and other metal foaming material, cement concrete, polyurethane, epoxy resin, nylon, phenol resin, thermoplastic plastic, PET (polyethylene terephthalate), SMC, carbon filler, and above-mentioned carbon fiber comprises the material of selling with trade mark KEVLAR.In addition, it is further contemplated that, carriage of the present invention or member, the wherein part of carriage perhaps of the present invention or member, can utilize or comprise a kind of material of selling with trade mark ISOTRUSS, as U.S. Patent No. 5 in promulgation on July 13rd, 1999,921,048 " truss structure such as three-dimensional ", on February 7th, 2002 " was waited truss structure " by the disclosed WO/0210535 of World Intellectual Property Organization, and the US Patent trademark office U.S. Provisional Patent Application that awaits the reply: " being used for being made by continuous fiber the method and apparatus of complicated composite structure " is illustrated and statement, they are all awarded jointly and give Brigham YoungUniversity, and therefore are included in herein as a reference.

It is further contemplated that, be used as the suitable material of any amount that carriage of the present invention or member are disclosed and state in this article, can form, carry by various conveying mechanisms known in this technology and system, or be placed in the aiming or selected part of a transport vehicle (that is, land, railway, sea or space flight automobile).For example, according to selected application or zone to be strengthened, material can cast, pumping, extruding, casting or is molded as desirable shape of any amount or solid.In addition, material can be reactive, non-reacted, inflatable, maybe can not expand, and can further utilize, install, or be filled in the carriage of hollow object, shell or a blowing, be used for above-mentioned carriage being placed within the selected part of vehicle during prefabricated or any state of manufacturing process.

Although utilizing this impact absorbing material and member is at a kind of vehicle frame, but can expect, the present invention can use in other zone of automobile, above-mentioned other zone is used for guaranteeing the ability of passenger and the two turnover automobile of goods, as dividing plate, guar plate, roof assembly, and this technology in known body in white (BIW) use.

Except utilizing along member the noise abatement material, according to desirable application requirements, the present invention can adopt the combination that strengthens expandable material on a kind of noise abatement material and a kind of structure along the different piece or the zone of member.Utilize sound absorption expandable material and structural materials conjugation, extra structural improvement can be provided, but mainly be to be mounted to improvement NVH (noise, vibration, top shake) characteristic.

Be used to make the material that absorbs impact or expandable material although disclose some, but material can be made with other material, as long as selected material is hot activation or passes through environmental conditions (such as conductive material, welding is used, moisture, pressure, time etc.) activate in addition, and under the selected appropraite condition of using with a kind of conclude with the failure-free mode expand.A kind of such material is at U.S. Patent application No.09/268, disclosed epoxy in 810, and above-mentioned patent application is awarded by the application and is allowed the people submit US Patent trademark office on March 8th, 1999, and its explanation is included in herein as a reference.Some other possible material comprises, but be not limited to, polyolefine material class, copolymer analog and ter-polymers class, phenolic materials class, phenoxy group material type, have the polyurethane material class of high glass transformation temperature, and can comprise even compound or composite material class that foam metal such as foamed aluminium are formed with at least a monomer type alpha-olefin.Also see: United States Patent(USP) Nos. 5,766,719; 5,755,486; 5,575,526; 5,932,680 (being included in herein as a reference).Generally, the desirable characteristic of some of expandable material comprises high rigidity, high strength, and high glass transformation temperature (usually greater than 70 ℃), and good adhesion confining force especially also are like this in having corrosive property or high temperature environment.

In some heat activated application, thermal expansion material should be arranged, relate to that the material that comprises structural foam is selected and a kind of important consideration of prescription is in the material reaction or expands and may solidify, with the temperature that takes place.In great majority are used, do not wish that material activates under the ambient temperature of room temperature or production line environment.More typically be that when foamed materials at high temperature adds man-hour with automotive components, structural foam is under higher processing temperature, and is reactive as becoming under those temperature that run in the automobile assembly plant.When the temperature that is run in car assembling body work shop stove can be in 148.89 ℃-204.44 ℃ (300-400) scopes, and paint shop's furnace temperature is generally about 93.33 ℃ (215 °F) or higher.If desired, various foaming agent activators can be added in the composition, expand so that under the different temperatures outside the above-mentioned scope, produce.

Generally, the inflatable acoustic foam material of prior art has a range of expansion and surpasses 1000% at about 100%-.The expansion level of material can be increased to up to 1500% or higher, but normally between 0% and 300%.Generally, higher expansion will make material production have lower strength and stiffness performance.

It is further contemplated that, can foam or expandable material can be carried and be placed into member and contacts by various delivery systems, above-mentioned feedway includes but not limited to, a kind of mechanical snap conjugative component, general known extrusion technique in this technology, and picture is according to total U.S. Patent No. 5,358, the described miniature coating machine technology of 397 (" technology that are used for the extruded plastic foam material ") is included in herein as a reference herein.In another embodiment, expandable material provides with sealing or part leak free form, above-mentioned expandable material comprises a kind of bead, but above-mentioned bead comprises a kind of expandable expanded material, above-mentioned expandable expanded material sealing or part are sealed in a kind of adhesive shell, expandable expanded material can be attached on the member with a kind of desirable structure then.The example of a this system is open in the total U.S. Patent No. that awaits the reply 09/524,298 (" expandable preforming plug "), and this paper comprises as a reference.In addition, preformed figure also can be used, as by extruded sheet (having a flat or shaped surface) and die-cut according to predetermined configuration then.

As mentioned above, each reinforcing section of the present invention is particularly useful for the occasion of hollow vehicle cavity reinforcement.When automobile heated, thermal expansion material (structural foam) expand into the surface of the predetermined hollow cavity of strengthening of contact.Need not be used to produce remarkable reinforcement through the thermal expansion material of overexpansion at inside face or other space filling of strengthening between the surface of member and hollow cavity.Usually preferably, hollow cavity incomplete flling is so that allow passage use for the moisture that flow condensation obtains.

A particular additional benefit of the present invention is that it can strengthen each big segmentation quite surely, so that the structural foam complete curing.Because material must be heated to cure, thus complete curing importantly produced, so that obtain optimum performance.If each very big segmentation filling structural foam then is difficult to obtain enough transfer of heats by material.Utilize a kind of compound reinforcement to increase greatly and produce completely crued possibility.Since it allow to utilize the inside face of the possibility of less hot activation foamed materials and rigidity reinforcement thermotropism active material provide a heat transfer conduit the two, this is possible.An extra benefit is can provide a kind of reinforcement with lower weight and lower cost to some kind of design.Another extra benefit is the possibility that it allows to produce a part, and an above-mentioned part during transportation high resistance is damaged, because the supporting member of the reinforcement of bonding is set on the hot expandable material.

Compound additional strengthening can constitute by with a kind of extruding machine the hot activation expandable material being assigned on the reinforcement, and above-mentioned extruding machine comprises a kind of by automatic control device pivotally attached extruding machine.This method relies on extruding machine to locate like this, so that the hot expandable material of fusing is assigned in the reinforcement.In when cooling, hot expandable material hardening, and when transportation resistance to deformation.When enough reheating (temperature must be higher than be used for the temperature of the hot expandable material of moulding), thermal expansion material will be activated, so that it will expand in hollow vehicle cavity and solidify, and thereby provide desirable reinforcement.Especially be to utilize the hinged extrusion press of automatic control device with material distribution to the optimal way on the reinforcement, so that the hot expandable material that will melt is pressed in each segmentation.A kind of other method is that this material with injection moulding is inserted on the additional strengthening.The another kind of method that constitutes this reinforcement is separately thermal expansion material to be extruded into a kind of shape, and above-mentioned shape is imitated the segmentation of a bonding position and then thermal expansion material slipped into or is snapped in the bonding segmentation of a bonding reinforcement.The another kind of extra method of making compound structure is that the melt with deformable heat expandable material is pressed in the bonding segmentation of reinforcement.

Alternatively, expanded material can be fastened on the reinforcement by for example pin.

The present invention figures in Fig. 1, and comprises a vehicle frame or rail energy management strength member system 10, and above-mentioned strength member system 10 forms according to explanation of the present invention.System 10 with a kind of make the ability that adds load and impact energy change of direction and the increase preferred part of giving an automobile, and therefore can be applied to the various application and the zone of an automobile or other moving vehicle.For example, energy management strength member system 10 can be used for just in case prevent each target of automobile when being impacted automobile external by exterior object and partly be out of shape and distort that above-mentioned each target partly comprises other used in vehicle frame, longeron, door or automobile framing member.System 10 is used for aiming at, regulating or management energy, is used to absorb and/or transfer to the other parts of automobile.As illustrated in fig. 1 and 2, the present invention includes at least one member 12, above-mentioned member 12 has an inside and an exterior section, this member 12 comprises the carriage of an injection moulding, above-mentioned carriage has the expandable material 14 of appropriate amount, above-mentioned expandable material 14 is molded on its each side, it can be laid by anchor fitting 18 (not shown), limit on the geometry, fixing or be adhered at least a portion of vehicle structure longeron or vehicle frame 16, said fixing device 18 is used for member 12 is placed in longeron or the vehicle frame 16.Anchor fitting 18 can comprise a displacement from interlocking assembly, gravity/geometry restriction, adhesion agent, a kind of assembly such as clip, distribution or buckle that is molded in the metal fastenings, Unitarily molded fastener such as a kind of clip, distribution or buckle and snap engagement assembly, above-mentioned snap engagement assembly is known in this technology.Shown in Fig. 3 and 4, anchor fitting 18 can comprise a clip.Vehicle frame or longeron 16 make automobile have structural integrity, and can be as the carriage of some body panels of automobile, and above-mentioned carriage can be seen from automobile external, and can receive impact energy.Be fixed on vehicle frame or the longeron 16 by the member 12 that will have expanding material 14, make member 12 be fixed in the vehicle frame at this place or the target of longeron 16 partly has additional structure reinforcement.

The present invention is used for this target reinforcement is placed in the selection area of a vehicle frame or longeron 16, and provide absorption, the guiding or the management impact energy ability, above-mentioned impact energy normally runs in the impact event process from external source or object, and is the sort of as what run in one front/off normal impact or collision process usually.Can expect that member 12 and expandable material 14 after expanding, produce a kind of composite structure, thereby the strength and stiffness of total system 10 are greater than each element sums.Just in case impact automobile external, just the target direction towards the automobile specific region manages impact energy by energy absorbing/dissipation or energy.

Energy management features of the present invention also can be utilized the displacement of targets of a plurality of drgs 20 along vehicle frame or longeron 16, and above-mentioned a plurality of drgs 20 are installed in the interior section of member 12 or are installed in the outside of member 12, as shown in Figure 1.Each drg 20 aimings or adjusting in addition, be used for selection area one of them or the two placement of vehicle frame or longeron 16 and/or a plurality of member 12, so that the layout that makes energy towards the aimed areas of automobile, and began to fold in the structure of axial collapse of inducting between impact epoch.As shown in Fig. 2-6, system 10 of the present invention can utilize a plurality of members 12 to be integrated in the automobile cavity, above-mentioned a plurality of member 12 one-tenth various reservation shapes, form and thickness, cavity size, shape and form that they are used corresponding to the selected special automobile that is used for energy management, but and do not damage the aesthetic quality of visual appearance, functional or automobile external partial sum painted surface.Any other step of one or more drgs 20 being installed and are integrated in the interior section of member 12 and being designed to breach, hole or component inside partial geometry shape changes.In some cases, each drg 20 can comprise the interior section of one section member simply, the unspecial application expandable material as shown in Figure 2 of the interior section of above-mentioned one section member.In other were used, a plurality of drgs 20 can utilize breach as shown in fig. 1, perhaps member 12 cut-out hole of a part wherein, also as shown in Figure 1.As illustrated in Fig. 3 and 4, drg 20 of the present invention comprises that also other step in a hole or member 12 geometric configuratioies changes, and above-mentioned step variation comprises the wall thickness that changes drg 20.

Expandable material 14 comprises that an impact energy absorbs, the structure reinforcement material, and the said structure reinforcement material forms rigidity or semi-rigid being fixed at least one member 12, and above-mentioned member 12 has at least one drg 20.Can expect that material 14 can be applied at least one member that becomes various different graphics, shape and thickness 12, so that adapt to specific size, the shape and size of cavity, the expandable material filling of above-mentioned cavity after activating.The layouts on member 12 12 surface itself along the layout of selected vehicle frame or longeron 16 and material 14 along member, and the especially interior section of member 12 and the layout of exterior section one of them or the two, can be applied in various figures and the thickness, so that aiming or energy management reinforcement and the distortion regulated in the automobile selection area reduce, the minimizing of impact energy or change of direction are used for limiting the damage car passenger carriage herein, and allow the passenger to pass in and out automobile.Material 14 is activated, so that finish expansion by applying heat, above-mentioned heat is coated with shove charge or is limited in other heating operation in the space between the member 12 at an automobile e usually and runs into, and above-mentioned member 12 is fixed on the vehicle frame or longeron 16 in alternative pre-production facility or the final motor vehicle assembly operation now.Formed composite structure comprises one by longeron or vehicle frame 16 formed wall constructions, and above-mentioned longeron or vehicle frame 16 join at least one member 12 by means of material 14.Have now found that, when material 14 is from L ﹠amp; L Products, Inc of Romeo, Michigan sells, as being in those materials that L-5204, L-5205, L-5206, L-5207, L-5208, L-5209, L-5214 and L-5222 provided when selected with the product grade, fixedly reach the best by the structure of utilizing member 12 and material 14.Fix for the vehicle frame by utilizing member 12 and material 14 or the half hitch structure of longeron 16, when material 14 is from L ﹠amp; L Products, Inc of Romeo, Michigan sell, and as being in those materials that L-4100, L-4200, L-4000, L-2100, L-1066, L-2106 and L-2108 provided when selected with the product grade, obtain optimum.

The performance of expandable material comprises the structural foam characteristic, and preferably hot activation is so that expand and curing when heating for above-mentioned foamed materials characteristic, and above-mentioned foamed materials characteristic normally combines the formation foam by release gas and finishes with the cross-linking chemistry reacting phase.Material 14 generally is to be applied on the member 12 with a kind of solid-state or semisolid.Utilize general known manufacturing technology, can become a kind of fluid state material 14 to be applied on the outside face of member 12, wherein material 14 is heated to a temperature, this temperature makes the expanded material can be mobile a little, so that help substrate wetting.When solidifying, material 14 hardening also adhere on the outside face of member 12.Alternatively, the bead that material 14 can be used as in advance casting is applied on the member 12, and above-mentioned bead heats a little, so that make these pillers join outside face on the member 12 to.In this stage, material 14 is heated to just enough mobile a little, but deficiency is so that material 14 het expansions.In addition, material 14 can also apply by heat bonding/Heat forming or by co-extrusion.Should be noted that other stimulates the material that can engage that activates to use, as, under limited case not, a kind of sealed type compound of some materials, said mixture is when by temperature, pressure, chemical method, or other environmental conditions one by one will become chemically active when activating.For this reason, an aspect of of the present present invention is convenient a kind of pipeline system manufacture method, thereby material 14 can be placed along member 12 by a desirable structure, wherein member 12 is fixed on vehicle frame or the longeron 16 by anchor fitting 18 then, is not perhaps having under the situation of anchor fitting how much formulas in any place before the automobile final assembly be restricted on vehicle frame or the longeron 16.Shown in Fig. 3 and 4, anchor fitting 18 of the present invention can comprise a clip, and above-mentioned clip is well-known in this technology.In this respect, system 10 of the present invention provides at least one, but may be a plurality of members 12, above-mentioned one or more member 12 is laid and is fixed thereon along selected vehicle frame or longeron 16 like this, so that the gap that keeps enough is used for existing and essential hardware, above-mentioned hardware can be placed in traditional auto body cavity inside, so that provide vehicle window to move, and door trim decorations etc.As shown in Figure 7, system 10 can also use in hydraulic forming is used, and wherein a plurality of locking part 12 is shaped, is used to be placed in the anchor fitting 18 of a closure, the device 18 that is fixed then limits, and said fixing device 18 comprises one from interlocking holding element.In specific hydraulic forming embodiment shown in Figure 7, drg 20 of the present invention comprises a hole or crushed element, and above-mentioned hole or crushed element run through locking part 12 interior sections, and drg 20 can also comprise that the step of locking part 12 wall thickness geometric configuratioies changes.

Disclosed energy management strengthening system 10 can use in various application among the present invention, above-mentionedly answer that use wishes that reinforcement is fastening, guiding and/or absorb impact energy, above-mentioned impact energy can be added on the framing member of automobile by external source or to the collision of automobile.As be in as shown in the Fig. 9 that impacts preceding state, system 10 can be used for by the system's bending that aims in a kind of progressive mode, warpage and destroy control and instruct energy management in the test of automobile frontal impact, and also being provided at certain reinforcement stability in the BENDING PROCESS simultaneously, above-mentioned BENDING PROCESS produces to impact in the system shown in the state of back in Figure 10.That is to say, as shown in Fig. 9 and 10, axial collapse can by with a plurality of drgs 20 relatively or the tangent bend mode produce.System 10 has special application in vehicle frame or longeron are used, to strengthen be a key factor to the overall weight of structure herein, and has one for strengthening and/or preventing by to the distortion that vehicle impact produced and the needs of distortion.For example, system 10 can be used for reducing or preventing the structural aberration of each several parts such as automobile, aircraft, automobile peculiar to vessel, fabric structure or other similar object, the structural capacity that each part mentioned above can experience a shock by nature or artificial mode or other applies.In the disclosed embodiment, system 10 is as the part of vehicle frame or longeron assembly, so that prevent automobile pass through in selected zone add the transfer of energy and/or absorb distortion, and can with the rocking arm in the automobile, rood beam, the engine in situ carriage, roof assembly, the roof arch, lifting gate, the roof head, purline, the guar plate assembly, columns assemblies, radiator/rad supporting member, bumper/spoiler, car bonnet in various body panels such as the automobile, baggage container, door, cargo box door, front-end architecture, door hits bolt, and can be near application together such as the other parts in the automobile of automobile external.Experienced technical personnel should be appreciated that, system can combine application with element of conventional insulation board and panel or a kind of vehicle structure strengthening system, perhaps use as an element of conventional insulation board and panel, as at generally accepted total U.S. Patent application Nos.09/524,961 or 09/502, disclosed in 686, this paper comprises that they as a reference.

Figure 11 illustrates U-shaped metal reinforcing core member 21, and structural foam band 22,23,24 is fixed on the outer wall of distribution 25 of chipware 21.Provide in addition and promote 26, above-mentioned distribution 26 can be used to reinforcement is fixed on the channel inner surface to be strengthened.

Figure 12 illustrates the part shown in Figure 11 that is arranged in front longitudinal divisions 27 lower member.When the upper component setting of front longitudinal divisions 27 and when being welded in the segmentation 27, pin 26 will be fixed to reinforcement on the upper component, and between the inside face of metal 22 and structural foam 24 and upper component, provide a space simultaneously, so that can effectively flow erosion resisting e application fluid.After coating e application fluid, so that coating is solidified, and structural foam expands during application with the segmentation baking, so that chipware is joined on the inside face of front longitudinal divisions.

Figure 13 is the scheme drawing of front rail longitudinal divisions shown in Figure 12, and Figure 13 illustrates the longeron 27 that has two curved section 28 and 29 simultaneously.First curved section is a curved section furthest away from the front of the car.In this embodiment, do not provide reinforcement in second curved section of longeron in front, second curved section is from the nearest curved section in automobile front.Reinforcing core member 21 illustrates strengthens curved section 28, and curved section 29 does not have reinforcement.Figure 14 is illustrated in when impacting how to guide energy at the reinforcement at segmentation 28 places, so that in the generation distortion of point of inflection 29 places rather than also in the generation distortion of point 28 places.

The preferred embodiments of the present invention are open.Yet those skilled in the art should be appreciated that some modification and is included in the technical scope of the present invention.Therefore, should study following claims, so that determine the actual scope and content of the present invention.

Claims (36)

1. be used for reducing or prevent and comprise in energy management system from the impact event automobile characteristic distortion of external force:

A) at least one member, described member have an inside and an exterior section, and said external partly is suitable for being placed in the cavity, and above-mentioned cavity is arranged in the chassis assembly; With at least one drg, above-mentioned drg is suitable for placing along the above-mentioned interior section of above-mentioned member; And

B) a kind of expandable material, above-mentioned expandable material are arranged on the wherein top of at least a portion of above-mentioned member.

2. the system as claimed in claim 1, wherein above-mentioned member comprises a plurality of drgs, above-mentioned a plurality of drgs are suitable for guiding the impact energy from external force.

3. system as claimed in claim 1 or 2, wherein above-mentioned member comprises a plurality of drgs, above-mentioned a plurality of drgs are suitable for absorbing the impact energy from external force.

4. as one of them described system of above-mentioned claim, wherein above-mentioned chassis assembly comprises a plurality of drgs, and above-mentioned a plurality of drgs are suitable for guiding the impact energy from external force.

5. as one of them described system of above-mentioned claim, wherein above-mentioned chassis assembly comprises a plurality of drgs, and above-mentioned a plurality of drgs are suitable for absorbing the energy from external force.

6. as one of them described system of above-mentioned claim, wherein above-mentioned member is suitable for strengthening the several portions of automobile, above-mentioned several portions is selected from following one group, described this group comprises a rail members, a frame member, a door assembly, a rocking arm and a vehicle frame rood beam member.

7. as one of them described system of claim 1-5, wherein above-mentioned member is suitable for strengthening the several portions of automobile, above-mentioned several portions is selected from following one group, described this group comprises a window frame, a car hold cover, a lifting gate, an automobile stand column assembly, and an automotive window.

8. as one of them described system of claim 1-5, wherein above-mentioned member is suitable for strengthening the several portions of automobile, and above-mentioned several portions is selected from following one group, described this group comprises a roof assembly, a roof arch, a purline, and a roof head.

9. as one of them described system of claim 1-5; wherein above-mentioned member is suitable for reducing the wherein impact energy distortion of several portions of automobile; above-mentioned several portions is selected from following one group, and described this group comprises a fender assembly, a bumper/spoiler and a preceding header structure.

10. as one of them described system of above-mentioned claim, wherein above-mentioned member comprises a kind of material, described material is selected from one group of material, and above-mentioned this group material comprises a kind of extruded aluminium, a kind of aluminum foam material, a kind of low density solid filler, a kind of molded magnesium alloy, a kind of magnesium foam material, a kind of titanium alloy, a kind of molded titanium alloy, and a kind of titanium foamed materials.

11. as one of them described system of above-mentioned claim, wherein above-mentioned member comprises a kind of material, described material is selected from one group of material, above-mentioned this group material comprises a kind of drawing cold-rolled steel, a kind of high strength low alloy steel of drawing, a kind of cold-rolled steel of rollforming, and a kind of high strength low alloy steel of rollforming.

12. for the member of using in a kind of system, be used for absorption and distribution according to external load management impact energy, above-mentioned member comprises:

A) first, described first are suitable for being placed in the qualifying part of automobile; And

B) second portion, described second portion is connected with above-mentioned first, above-mentioned second portion has a surface that is suitable for installing a kind of expandable material, and above-mentioned expandable material helps to absorb according to above-mentioned load when expanding and distributes impact energy on above-mentioned surface.

13. member as claimed in claim 12, also comprise a third part, described third part is connected with one of them of above-mentioned first and second portion, and above-mentioned third part has a plurality of drgs, and above-mentioned a plurality of drgs are suitable for guiding the impact energy from an external force.

14. as claim 12 or 13 described members, also comprise a third part, described third part is connected with one of them of above-mentioned first and second portion, and above-mentioned third part has a plurality of drgs, and above-mentioned a plurality of drgs are suitable for absorbing the impact energy from an external force.

15. as one of them described member of claim 12-14, wherein above-mentioned member is suitable for strengthening the several portions of automobile, the several portions of above-mentioned automobile is selected from one group, described this group comprises a rail members, a frame member, a door assembly, a rocking arm, and a vehicle frame rood beam member.

16. as one of them described member of claim 12-14, wherein above-mentioned member is suitable for strengthening the several portions of automobile, the several portions of above-mentioned automobile is selected from one group, described this group comprises a window frame, an automotive deck roof, a lifting gate, an automobile principal post assembly, and an automotive window.

17. as one of them described member of claim 12-14, wherein above-mentioned member is suitable for strengthening the several portions of automobile, and the several portions of above-mentioned automobile is selected from one group, and described this group comprises a roof assembly, a roof arch, a purline and a roof head.

18. as one of them described member of claim 12-14, wherein above-mentioned member is suitable for reducing the impact energy distortion of automobile several portions, above-mentioned automobile several portions is selected from one group, and described this group comprises a guar plate assembly, a bumper/spoiler and a front-end architecture.

19. as one of them described member of claim 12-18, wherein above-mentioned member comprises a kind of material, and described material is selected from one group of material, and described this group material comprises extruded aluminium, a kind of aluminum foam material, a kind of low density solid filler, a kind of magnesium alloy, a kind of molded magnesium alloy, a kind of magnesium foam material, a kind of titanium alloy, a kind of molded titanium alloy, and a kind of titanium foam material material.

20. as one of them described member of claim 12-18, wherein above-mentioned member comprises a kind of material, described material is selected from one group of material, above-mentioned this group material comprises a kind of drawing cold-rolled steel, a kind of drawing high strength low alloy steel, a kind of rollforming cold-rolled steel and a kind of rollforming high strength low alloy steel.

21. as one of them described member of claim 12-20, wherein above-mentioned expandable material is a kind of polymeric material with foam characteristics.

22. as one of them described member of claim 12-21, wherein above-mentioned expandable material is a kind of epoxy resin base polyalcohol material with foam performance.

23. as one of them described member of claim 12-22, wherein above-mentioned expandable material is a kind of heat activated expandable polymer material.

24. as one of them described member of claim 12-23, wherein above-mentioned expandable material is a kind of generally to contacting tack-free expandable plastic.

25. as one of them described member of claim 12-24, wherein above-mentioned expandable material is the expandable plastic that can activate under a kind of temperature that is run in the automotive paints operation.

26. impact distortion minimizing system, comprising:

A) chassis side rail, described chassis side rail are provided as framing member usefulness in the automobile, and above-mentioned chassis side rail has the surface portion that exposes;

B) at least one member, described member installing type join on the surface portion that exposes of above-mentioned chassis side rail; And

C) a kind ofly be used to manage the impact energy expandable material, above-mentioned expandable material is arranged on the wherein top of at least a portion of above-mentioned member.

27. system as claimed in claim 26, wherein above-mentioned expandable material is a kind of ethene polymers based polyalcohol foamed materials.

28. as claim 26 or 27 described systems, wherein above-mentioned expandable material is a kind of hot activation formula expandable polymer foamed materials.

29. as one of them described system of claim 26-28, wherein above-mentioned expandable material is a kind of generally to contacting tack-free expandable polymer foamed materials.

30. as one of them described system of claim 26-29, wherein above-mentioned expandable material is the expandable vinyl foamed materials that can activate under a kind of temperature that runs in the automotive paints operation.

31. as one of them described system of claim 26-30, wherein above-mentioned expandable material is a kind of hot activation formula thermoplastic foamed material.

32. as one of them described system of claim 26-31, wherein above-mentioned expandable material is a kind of generally to contacting adeciduate expandable vinyl foamed materials.

33. be used for the energy management stiffening device of automobile, comprise:

A) chassis side rail, described chassis side rail are suitable for being placed in the several portions of automobile, and above-mentioned several portions has exterior portion of a inside partial sum, limits a cavity in the partial sum exterior portion of above-mentioned the inside;

B) at least one member, described member is placed in the above-mentioned frame member and is arranged in the above-mentioned cavity, above-mentioned member has a kind of expandable material, described expandable material becomes sealing contact with above-mentioned member, above-mentioned expandable material is suitable for expanding being exposed to when pining for, thus with above-mentioned member engages at least on one of them of the above-mentioned interior section of above-mentioned chassis side rail and exterior section;

C) above-mentioned at least one member also comprises a plurality of drgs that are used to manage impact energy, and above-mentioned impact energy is applied on the automobile by external force.

34. structure reinforcement, described structure reinforcement comprises a kind of chipware, on the part on said structure reinforcement surface one or more structural foam parts are being fixed on the above-mentioned chipware, reinforcement has the device that is used for fixing on the member to be strengthened, the device that wherein is used for fixing is like this, promptly before forming foamed materials, at chipware, provide a space between structural foam and the inner surface of component to be strengthened, with formation foamed materials process structural foam is expanded and stride across above-mentioned space, and chipware is joined on the inner surface of component to be strengthened, and between core and framing member, stay passage simultaneously.

35. according to the described structure reinforcement of claim 34, wherein structural foam covers the 20%-45% on chipware surface.

36., be used to strengthen the front longitudinal divisions of automobile according to claim 34 or 35 described framing members.

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