CN1646288A - 改进的车辆结构部件及制造这些部件的方法 - Google Patents

改进的车辆结构部件及制造这些部件的方法 Download PDF

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CN1646288A
CN1646288A CNA038083183A CN03808318A CN1646288A CN 1646288 A CN1646288 A CN 1646288A CN A038083183 A CNA038083183 A CN A038083183A CN 03808318 A CN03808318 A CN 03808318A CN 1646288 A CN1646288 A CN 1646288A
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D·G·麦克劳德
F·V·比约托
S·B·斯沃茨米勒
M·P·艾伦
C·A·布鲁斯特
K·赛义德
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Abstract

本发明是一种构件，其包括：成形的硬质泡沫元件(10)；直接施加到成形泡沫元件外表面至少一部分上的热激活可发泡胶粘剂(30)；和整体定位装置(40)。本发明的第二方面是一种形成填充车辆空心部件泡沫的方法，包括：(a)将硬质泡沫元件(10)插入车辆空心部件(5)内，该硬质泡沫元件包括在硬质泡沫填充物的至少一部分上具有热激活可发泡胶粘剂的硬质泡沫和从硬质泡沫表面伸出的至少一个整体定位装置，(b)将定位装置(40)与空心部件(5)结合，以在空心部件内定位硬质泡沫元件(10)，以及(c)将其内具有硬质泡沫元件的空心部件加热到足以将热激活可膨胀胶粘剂(30)激活的温度和时间，以形成填充车辆空心部件的泡沫。

Description

改进的车辆结构部件及制造这些部件的方法
技术领域
本发明涉及轻质填充物，其用于提高结构整体性或减轻诸如汽车的框架杆或柱之类的车辆结构部件的声音。
背景技术
减少机动车重量一直很重要并且仍将很重要，以满足日益苛刻的燃料经济性和环境标准的要求。一直以来都期望汽车更安静更安全。为了满足这些矛盾的需求，汽车工程师在车辆空腔内引入了泡沫以主要地用来减小噪声(声学泡沫)。这些泡沫通常在部件形成后被引入该结构部件的空心区域。也通过当部件形成时在空心部件内插入可发泡材料，并且随后在例如E-涂覆(E-coating)过程中，发泡该可发泡材料而引入该泡沫。
因为对于每个车辆，泡沫一直难于精确定位，并难以包含在空心结构部件的特定区域内，所以它们一直没有用于提高例如结构部件的刚性。这种不能确切知道泡沫在何处以及泡沫填充空腔到何种程度的情况，导致每个车辆的耐撞性的不可预测性和变化性。例如，在结构部件内设计的碰撞区可能包含不想要的泡沫，导致过剩的能量在事故中被传送给车辆的乘客，反之，没有充分填充空腔的泡沫也能够导致相似的问题。
这种不受控制的发泡和空腔填充也导致如下问题：例如泡沫溢出并堵塞诸如用于其它组件的安装孔之类的功能孔。另一个问题是如果泡沫在制造过程中插入并且随后在E-涂覆的过程中受热而发泡，那么该泡沫可能会被用于制造空腔的焊接过程发泡。
在美国专利US5194199(‘199专利)中描述了将泡沫引入车辆空心部件的方法的实例。在‘199专利中，描述了封装在热塑性塑料内的具有聚氨酯反应物壳体(可热发泡壳体)的泡沫芯。例如在浸渍涂覆过程中，当受到足够热量时该壳体会发泡。该芯被引入空心部件(例如具有类似“C”形的横截面的梁)的一部分内，该空心部件具有从芯延伸出的连接部件。该方法需要局部凸起，使得当通过例如将面板焊接到C形梁上而形成该空心部件时，被封装的聚氨酯的可热发泡的壳体不会发泡。
在US5678826中，描述了一种引入泡沫的方法，其中可发泡的材料通过延伸穿过空心部件的壁的可拆卸插头而安置在空心部件内。在E-涂覆的过程中当可发泡材料发泡之后，除去该插头。在EP 0999119 A2中，描述了一种引入泡沫的方法，其中在该泡沫内，该泡沫具有排泄通道。这些现有技术方法中每一个都不能解决在空心部件内精确定位和放置泡沫的问题。另外，它们不能解决如下问题：泡沫堵塞空心部件内的孔，这些孔用于将其它零件安装到部件上，或者为其它零件在部件内留出路径，这些零件例如是在泡沫已经被引入空心部件内之后可通过该空心部件的线。
因此，需要提供一种用于将泡沫引入车辆空心部件的方法，该方法解决了现有技术的一个或多个问题，例如解决了上面所描述的那些问题中的一个。也需要提供一种发泡的填充物，其帮助提供了解决现有技术的一个或多个问题的方法，所述问题为，例如上面所描述的那些问题。
发明内容
本发明的目的包括、但不限于以下内容：(1)将硬质泡沫插入车辆的空心部件的方法，使得该泡沫精确地定位在空心部件内，(2)易于判断泡沫在空心部件内存在的方法，(3)可以方便地插入到空心部件内并随后在E-涂覆过程中结合到空心部件上的发泡前的填充物，但是在空心部件形成(例如焊接)过程中不进行粘性结合，(4)将泡沫插入空心部件的方法，其不会堵塞在空心部件的壁内的功能孔，以及(5)在泡沫和空心部件的壁之间形成通道的方法，该通道能够用于E-涂覆的排泄并且也可用作安装其它诸如制动管或线路之类的车辆硬件的管路。
本发明的第一方面包括一种构件，该构件包括：成形的硬质泡沫元件；热激活可发泡的胶粘剂，该胶粘剂直接涂覆在成形的泡沫元件的外表面的至少一部分上；和整体的定位装置。
本发明的第二方面涉及形成填充车辆空心部件泡沫的方法，包括：
(a)将由硬质泡沫和至少一个整体的定位装置组成的硬质泡沫元件插入车辆空心部件内，其中所述硬质泡沫在硬质泡沫填充物的至少一部分上具有热激活的可发泡的胶粘剂，所述定位装置从硬质泡沫的表面伸出，
(b)将定位装置与空心部件相结合，以在空心部件内定位硬质泡沫元件，以及
(c)将在其内具有硬质泡沫元件的空心部件加热到一定温度并保持一定时间，所述温度和时间足以将热激活可膨胀胶粘剂激活，以形成填充车辆空心部件的泡沫。
本发明允许硬质泡沫元件精确地插入到车辆空心部件内，同时也使得在生产中更易于确定泡沫在空心部件内的存在(也即对于销的观察)。本发明的方法特别适用于形成车辆的结构体，例如汽车的框架杆(frame rail)。例如，对于汽车的框架杆来说，具有弱化的部分以产生碰撞区来消散事故的能量并保护乘客是很普通常见的。框架杆也支撑像变速箱这样的汽车元件。该方法允许诸如聚氨酯泡沫之类的泡沫可选择地被引入框架杆内，而不危及碰撞区或者堵塞用于诸如引擎和变速箱之类的其它组件的安装孔。该方法也用于制造车辆的其它组件，例如车门下围板、梁、柱、横杆和主体支架。该方法也可以用于其它应用，例如竞技设备、船、自行车、飞行器、卡车和火车。
附图说明
图1是在封闭空心部件之前，在其内具有填充物的车辆空心部件的横截面视图。
图2是在封闭空心部件之后但在可热膨胀胶粘剂膨胀之前，在其内具有填充物的车辆空心部件的横截面视图。
图3是在可热膨胀胶粘剂膨胀之后，在其内具有填充物的车辆空心部件的横截面视图。
图4示出了本发明填充物的另一实施例。
图5从相反侧示出了图4所示的填充物的视图。
具体实施方式
此处使用的空心部件是指由诸如汽车这样的装置上的多个元件形成的空的腔体，该腔体通常是封闭的。该装置在空心部件的位置处会显示出结构上的薄弱。相对于在成形的泡沫构件上的胶粘剂的位置的至少一部分，意味着该成形的泡沫构件在其一些或全部外表面上具有胶粘剂。整体的定位装置是用于将该成形元件定位和保持在想要放置的位置的装置，其中该定位装置与成形元件形成一个整体。该整体的定位装置可以是由用于形成成形元件的泡沫制成的成形凹槽或凸起。作为选择，该整体的定位装置由另一种材料制成，其中该定位装置的一部分被模制成成形泡沫元件或者在模制后永久地固定，以便永久地将整体的定位装置锁定在适当位置上。该整体的定位装置可以是用于将所述元件焊接在适当位置上的金属键片、适于接收螺钉的螺纹插入物，其中该螺钉被设计成用来将所述元件保持在适当位置上。该整体的定位装置可以是任何部件，其中该部件一部分模制成硬质泡沫元件，并且该部件之外的部分具有适于机械地保持该部件在一位置上的机械固定装置，例如咬合装配夹(snap fit clip)或夹子。机械固定装置是任何已知的用于保持元件在其适当位置的机械装置，包括咬合装配夹、螺栓、螺丝等等。整体的定位装置的全部或者一部分可以是磁性的。该整体的定位装置也可以是在外面部分上具有压敏胶粘剂的模制元件。
在一个实施例中，该整体的定位装置是从硬质泡沫表面伸出的定位销。该定位销的一部分可以在制造该硬质泡沫填充物时，模制到硬质泡沫填充物中或者由硬质泡沫形成。优选地，该空心部件具有装配定位销的配合定位孔，以将硬质泡沫填充物定位在适当位置上。当硬质泡沫填充物放入空心部件内时，该定位销插入所述定位孔，以便将硬质泡沫定位在合适位置。
此处所用的“结合”一词是指使用定位装置将硬质泡沫填充物放置于空心部件内处在合适的位置。在优选的实施例中，定位装置也能够用于将硬质泡沫填充物保持在合适位置，这种保持可以是永久的也可以直到可发泡的胶粘剂膨胀接触到空心部件的壁为止，并且因此将硬质泡沫填充物保持在合适位置。结合也可以指用整体的定位装置将硬质泡沫填充物保持在合适位置。这能够通过以下方式获得：通过焊接金属键片到空心部件上；将其上具有压敏胶粘剂或磁体的定位装置放置在胶粘剂或磁体与空心部件相接触的位置；或者通过在空心部件的适当位置采用机械固定装置，将硬质泡沫填充物保持在适当的位置。在该整体的定位装置是用于螺钉的螺纹插孔的情况下，可以结合外部的螺丝。此处使用的“成形的”是指具有适于装配入空心部件的三维形式。在整体的定位装置中所使用的“整体的”是指该定位装置不仅仅是暂时连接到该泡沫填充物上，而是在这种连接中，如果将该定位装置去除，则该定位装置将会被破坏或者该填充物泡沫将会被损坏。通常，这意味着该定位装置是该填充物泡沫的一个连续的部分，该部分被模制在填充物泡沫内或者粘着结合到填充物泡沫上。
在一优选实施例中，本发明是一种用于形成填充车辆空心部件的泡沫的方法，该方法包括：
(a)将由硬质泡沫组成的硬质泡沫填充物插入具有至少一个孔的车辆空心部件内，其中该硬质泡沫在硬质泡沫填充物的至少一部分上具有热激活可发泡胶粘剂和从该硬质泡沫表面伸出的至少一个整体的定位销，使得当插入时，该填充物的定位销插入空心部件的孔内，致使该硬质泡沫填充物定位并保持在空心部件内，以及
(b)加热在其内具有硬质泡沫填充物的空心部件达到一定的温度和时间，该温度和时间足够将热激活可膨胀胶粘剂激活，以形成填充车辆空心部件的泡沫。
在一优选实施例中，本发明是一种形成填充车辆空心部件的泡沫的方法，包括：
(a)插入由成形的硬质泡沫组成的成形的硬质泡沫元件，其中该成形的硬质泡沫在硬质泡沫元件的至少一部分上具有热激活可发泡胶粘剂和从该硬质泡沫元件表面伸出的至少一个整体的定位装置；
(b)将硬质泡沫元件的定位装置与空心部件相结合，以在空心部件内定位该硬质泡沫填充物；以及
(c)加热在其内具有硬质泡沫元件的空心部件达到一定的温度和时间，该温度和时间足够将热激活可膨胀胶粘剂激活，以形成填充车辆空心部件的泡沫。
在一优选的实施例中，本发明是一种方法，其中该定位装置是具有适于接收螺丝的螺纹的模制填充物，并且通过将螺丝插入穿过空心部件的孔并将螺丝拧入带螺纹的填充物内，而使该硬质泡沫填充物与空心部件相结合。
在一优选的实施例中，本发明是一种方法，其中该定位装置是金属键片，并且该硬质泡沫通过将金属键片焊接或者铆接到空心部件上而与空心部件相结合。
图1-3示出了本发明的具体实施例，并且绝非以任何方式限制了本发明的范围。参照图1的具体实施例，填充车辆部件5的泡沫通过将硬质泡沫填充物10插入金属壁20的空腔内而形成，该金属壁20具有定位孔21和安装孔22。该硬质泡沫填充物10上具有热激活胶粘剂30。刚性芯具有至少一个整体的定位销40，定位销40从硬质泡沫填充物10的表面100伸出。该定位销40可以包括具有底座表面60的定位底座50和延伸穿过孔21的定位凸柱70。该泡沫填充物10也可以具有胶粘剂挡圈90，其保护安装孔22在加热和所述胶粘剂膨胀时不被可膨胀的胶粘剂30堵塞。填充后的部件5也可以具有由胶粘剂挡圈120泡沫、表面130和金属壁20形成的管路110。该填充后的部件也可以具有临时的排泄通道140，该排泄通道140由在其上具有胶粘剂30的泡沫填充物的表面150和金属壁20限定。
如图2所示，在泡沫填充物10插入由金属壁20所限定的空心部件之后，金属壁160放置在金属壁20之上并焊接在金属延伸部分170和180上。焊接之后，内表面190被E-涂覆，并且由于E-涂覆的过程中的加热，胶粘剂30膨胀并形成如图3所示的填充了车辆部件5的泡沫。
填充物泡沫10的插入可以通过任何合适的方法完成，例如用手工将它放入由金属壁20所限定的空腔内，只要定位销40延伸穿过定位孔21即可。整体的定位销40可以由任何材料制成，但是优选是与泡沫填充物10相同的材料。优选地，该销40和填充物10同时形成为一体。该销优选具有底座50和凸柱70。在销40的该优选实施例中，胶粘剂30需要一定具有厚度，以使该胶粘剂与底座表面60同水平高度。为了便于泡沫填充物10的定位，优选底座表面60上具有胶粘剂，该胶粘剂在可膨胀的胶粘剂30受热和膨胀之前，将填充物10粘到金属壁20上。在底座表面60上的胶粘剂可以是任何合适于在泡沫填充物10和金属壁20之间形成结合的胶粘剂。销表面75可以被油漆成与金属壁20显著不同的颜色，使得易于确定泡沫填充物10是否处在车辆部件5之内。
整体的定位销40可以是任何合适的横截面形状。例如，该销的横截面可以是圆形、椭圆形、正方形、矩形或任何其它有用的多边形。
泡沫填充物10可以是任何合适的泡沫材料。如果允许不受限制的选择泡沫，该泡沫材料将优选具有从5磅/立方英尺(80Kg/m3)到25磅/立方英尺(400Kg/m3)的密度。具体泡沫的选择将取决于车辆部件所需的性能。优选地，该泡沫材料是聚氨酯热固性聚合物泡沫。然而，也可以使用其它结构填充物材料类型，例如，包括环氧树脂、聚氨酯混合物的其它热固性和热塑性填充物，例如聚亚安酯(聚异氰脲酯)、聚烯烃、间规立构物、组合物和其它硬质泡沫。非塑料填充材料，例如铝泡沫、有机和无机(陶瓷和金属)泡沫也可以使用。
该泡沫填充物10可以由任何合适的方法制造，例如，那些在本技术领域公知的用于模制聚合刚性或弹性泡沫的方法。作为示例，其成分一般包括聚合物或单聚物和发泡剂。在优选实施例中，一个实例是由“A部分(A-side)”和“B部分(B-side)”成分结合而产生的泡沫，其中这部分在环境条件下凝固。例如A部分可以由异氰酸脂预聚物或聚合的亚甲基联苯异氰酸脂(MDI)组成，B部分可以由名义上的多元醇混合物组成，该多元醇混合物由各种多元醇、表面活化剂、催化剂和水组成。该泡沫也可以包含诸如玻璃珠、触变添加剂和其它复合纤维之类的填充物。也可以使用化学或物理的发泡剂或其组合。也可以使用单成分发泡方法，例如在美国专利4923902和4995545中所描述的那样。泡沫填充物也可以使用相应待批的美国申请09/998093中所描述的方法来制造。
可膨胀的胶粘剂30也可以是本技术领域公知的那些任何合适的胶粘剂。在E-涂覆之前，要求可膨胀胶粘剂30不会被随后诸如焊接这样的过程所激活。典型的可膨胀胶粘剂包括诸如环氧树脂或乙烯基聚合物之类的聚合基材料，当用合适成分(通常为发泡和凝固剂)混合时，在受热的情况下，例如在E-涂覆过程中，该聚合基材料以可靠和可预计的方式膨胀和凝固。该可膨胀胶粘剂在固化或获得它的最终形状时也会产生交联，使该材料变得不能够进一步流动或形状变化。其它有用材料包括聚烯烃、具有至少一个单聚物类型阿尔法烯烃的共聚物和三元共聚物、苯酚/甲醛材料、含苯氧基材料、以及具有高玻璃化转变温度的聚氨酯材料，例如美国专利US.5766719、5755486、5575526和5932680中所公开的材料。优选可膨胀胶粘剂30为环氧树脂或者合成橡胶胶粘剂，例如含双环戊二胺(EPDM)类型的胶粘剂、实例为ND 700，其从密歇根州特洛伊的ND工业公司(ND Industries Inc.，Troy，Michigan)可获得。
可膨胀胶粘剂30可通过任何方式施加到泡沫填充物10的外表面，包括浸、层压、刷、滚动共挤(rolling co-extruding)、注模、软性塑料包覆硬质塑料成形法(overmolding)和喷涂。另外，可膨胀胶粘剂30能够预制成或模切割(die-cut)成片，其能够放置或者粘贴到泡沫填充物10上。
泡沫填充物10也可以具有保护安装孔22的胶粘剂挡圈90。需要的话，在泡沫填充物10上的任何胶粘剂挡圈都由泡沫填充物10的泡沫材料制成。这些挡圈可以在填充物由合适的材料形成之后使用另一种材料制成，例如能够承受在制造车辆过程中所经受的温度而不变形并且不允许可膨胀胶粘剂30渗出挡圈的合成塑料。实例包括诸如尼龙、聚碳酸酯、聚酯、环氧树脂和苯酚甲醛树脂之类的塑料。
泡沫填充物10也可以包含管路110和临时通道130。这些部分可以根据需要模制在泡沫填充物10内，但也可以由后续的机械方式，通过切割或去除泡沫填充物10的一部分而制成。该临时排泄通道130用于排泄例如在E-涂覆过程中使用的液体。管路110用作需要保护的车辆零件的管路，所述车辆零件诸如配线、气管和制动管。
本发明的泡沫填充物能够被放入空心部件中以提高装置的结构整体性，从而阻止声音或/和振动传送穿过空心部件。
图4和5示出了根据本发明的填充物另一实施例的两面。图4和5显示了模制的填充物210，该填充物210的大部分表面上具有胶粘剂220。所示三个模制嵌入的金属键片230都具有定位部分240，通过定位部分240键片230被模制在填充物210内。图中示出了填充物210的第二组位置250，在位置250处胶粘剂不覆盖填充物210。金属键片230能够将填充物210焊接在在空心部件中的适当位置上，从而形成了整体的定位装置。

Claims (10)

1.一种构件，其包括：成形的硬质泡沫元件；热激活可发泡的胶粘剂，该胶粘剂直接施加到所述成形的硬质泡沫元件的外表面的至少一部分上；和整体的定位装置。
2.如权利要求1所述的构件，其中，所述整体的定位装置是位于硬质发泡元件内的成形的凹槽或凸起；第二元件部分地模制在所述硬质泡沫元件内，其中第二元件的所述部分也从该元件凸出并且适于将所述硬质泡沫元件定位在空心部件的适当位置。
3.如权利要求1或2所述的构件，其中，所述定位装置是定位销、金属键片、具有压敏特性或磁体的凸起、具有适于接收螺丝的填充物、或局部模制在第二元件内的定位件，其中所述从硬质泡沫填充物凸出的第二元件的所述部分是机械固定装置。
4.一种形成填充车辆空心部件的泡沫的方法，包括：
(a)将根据权利要求1到3中任何一项所述的成形的硬质泡沫元件插入空心部件内；
(b)将硬质泡沫元件的定位装置与空心部件相结合，以在空心部件内定位该硬质泡沫填充物；以及
(c)将在其内具有硬质泡沫元件的空心部件加热到足以将热激活可膨胀胶粘剂激活的温度和时间，以形成填充车辆空心部件的泡沫。
5.如权利要求4所述的方法，其中，所述定位装置是金属键片，并且所述硬质泡沫通过将金属键片焊接到空心部件上而与该空心部件相结合。
6.如权利要求4所述的方法，其中，所述定位装置是具有适于接收螺丝的螺纹的模制填充物，并且所述硬质泡沫填充物通过将螺丝插入穿过空心部件内的孔并将螺丝拧入带螺纹的填充物内而与所述空心部件相结合。
7.如权利要求4到6中任何一项所述的方法，其中，所述硬质泡沫填充物在其表面上具有至少一个胶粘剂挡圈，当可膨胀的胶粘剂膨胀时，所述挡圈使所述泡沫填充物的至少一部分不会带有可膨胀的胶粘剂。
8.如权利要求4到7中任何一项所述的方法，其中，在步骤(b)的加热以前，填充空心部件的泡沫具有临时排泄通道，该排泄通道由泡沫填充物壁和车辆空心部件壁所限定。
9.如权利要求4到8中任何一项所述的方法，其中，填充空心部件的车辆泡沫具有至少一个由泡沫填充物壁和车辆空心部件壁所限定的管路。
10.如权利要求4到8中任何一项所述的方法，其中，所述加热在E-涂覆过程中进行。
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US7838100B2 (en) 2010-11-23
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IN2004CH02299A (zh) 2007-09-07
WO2003089221A1 (en) 2003-10-30
BR0309088A (pt) 2005-02-09
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US7097794B2 (en) 2006-08-29
AU2003226364A1 (en) 2003-11-03
KR100931762B1 (ko) 2009-12-14
KR20040101474A (ko) 2004-12-02
US20060188694A1 (en) 2006-08-24
JP2009292476A (ja) 2009-12-17
CN100553929C (zh) 2009-10-28
US20030194548A1 (en) 2003-10-16

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