EP1109713A1 - Three dimensional laminate beam structure - Google Patents

Three dimensional laminate beam structure

Info

Publication number
EP1109713A1
EP1109713A1 EP99943755A EP99943755A EP1109713A1 EP 1109713 A1 EP1109713 A1 EP 1109713A1 EP 99943755 A EP99943755 A EP 99943755A EP 99943755 A EP99943755 A EP 99943755A EP 1109713 A1 EP1109713 A1 EP 1109713A1
Authority
EP
European Patent Office
Prior art keywords
polymer
shell
core insert
foam
insert
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP99943755A
Other languages
German (de)
French (fr)
Other versions
EP1109713A4 (en
Inventor
Joseph S. Wycech
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Henkel Corp
Original Assignee
Henkel Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Henkel Corp filed Critical Henkel Corp
Publication of EP1109713A1 publication Critical patent/EP1109713A1/en
Publication of EP1109713A4 publication Critical patent/EP1109713A4/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/001—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
    • B29C39/02—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C39/10—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. casting around inserts or for coating articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/1228—Joining preformed parts by the expanding material
    • B29C44/1242—Joining preformed parts by the expanding material the preformed parts being concentric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/70—Completely encapsulating inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/001—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material
    • B62D29/002—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material a foamable synthetic material or metal being added in situ
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D65/00—Designing, manufacturing, e.g. assembling, facilitating disassembly, or structurally modifying motor vehicles or trailers, not otherwise provided for
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/14—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being a lining
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60G—VEHICLE SUSPENSION ARRANGEMENTS
    • B60G2206/00—Indexing codes related to the manufacturing of suspensions: constructional features, the materials used, procedures or tools
    • B60G2206/01—Constructional features of suspension elements, e.g. arms, dampers, springs
    • B60G2206/013—Constructional features of suspension elements, e.g. arms, dampers, springs with embedded inserts for material reinforcement

Definitions

  • Hydra-formed metal sections may have curved three-dimensional geometry.
  • reinforcing the section or component is very difficult because the location of the hydra-formed section that is critical and decides the overall performance of the component, is often the section located at a major discontinuity "notch" or curvature .
  • An object of this invention is to provide a reinforced beam of curved geometry.
  • a further object of this invention is to provide techniques for reinforcing such a beam.
  • the beam is a hollow structure.
  • a pre-molded foam core is inserted into the hollow structure spaced from at least one inside wall of the hollow structure.
  • a polymer is pumped in and around the foam core insert so that after curing the polymer bonds to the inside wall of the structure.
  • the structure is a hydra-formed metal section, such as a vehicle control arm assembly.
  • the pre-shaped foam insert is preferably made of a lightweight material to minimize the weight of the final laminate beam formed by the invention.
  • Figure 1 is a perspective view of a laminated control arm assembly beam in accordance with this invention.
  • Figure 2 is a cross-sectional view taken through Figure 1 along the line 2-2.
  • the present invention is particularly useful for reinforcing hollow sections or structures, which are of curved geometry and/or located at locations, which are relatively inaccessible.
  • the hollow structure is a metal section, such as a hydra-formed metal section with curved three-dimensional geometry.
  • An example of such section is a control arm assembly, wherein it is desired to reinforce the control arm beam.
  • the critical portion which requires reinforcement in order to maximize the overall performance of the component is often the portion at a major section discontinuity "notch" or curvature.
  • Figure 1 illustrates an automotive control arm assembly beam 10 made of a hydra-formed metal shell 12 of conventional size and shape and structure such as including through holes 14 and end walls 16. As can be seen the shell 12 has a three dimensional geometry which is non-uniform from end wall to end wall and which is curved.
  • a preformed foam core 18 is inserted into the hollow or cavity of shell 12.
  • Core 18 is spaced away from at least one inside wall of the hollow shell 12 and is shaped to extend along at least one side of the shell .
  • Core 18 functions to locate a reinforcing polymer 20 within the hollow shell so that after curing the polymer will bond to and reinforce the inside wall of the shell.
  • Core or insert 18 is made of a lightweight pre-shaped or preformed material such as urethane, phenolic or expanded polystyrene.
  • the polymer 20 would be pumped in and around the foam core 18 so as to be located in the space between core insert 18 and the inner wall of shell 12.
  • Polymer 20 is then cured such as being heat cured or ambient temperature cured.
  • polymer 20 is bonded to the inner wall of shell 12 and to foam core 18 to function as a structural foam.
  • the polymer or structural foam may be, but is not necessarily an expandable foam.
  • the curing of the polymer could be accomplished in any suitable manner.
  • the polymer could be heat cured in an oven such as an e-coat oven during the manufacturing of the vehicle.
  • the polymer could be cured at ambient temperatures such as, for example, about 77 * F.
  • the foam core insert 18 may be pre-shaped in a geometry which generally conforms to the inner surface of shell 12 thereby minimizing the amount of polymer material required to fill the remaining open space within shell 12.
  • core insert 18 may be of uniform cross- sectional shape throughout all or most of its length to simplify the structure of the core insert, but which would result in a greater amount of open space.
  • the foam core insert 18 thus comprises a three-dimensional or essentially two dimensional molded pre-formed part which occupies some of the volume or space within shell 12 and provides a substrate for the polymer 20 which is pumped into the shell 12.
  • the invention thus results in a three-dimensional laminate beam, which is formed by pumping the polymer around the pre-molded foam core. This is the only means necessary to reinforce such a hydra-formed metal section.

Abstract

A three-dimensional laminate beam (10) is formed by inserting a preformed foam core (18) insert within a hydra-formed metal section (12) having curved three-dimensional geometry. A reinforcing polymer (20) is pumped in and around the foam core insert so as to be adjacent the inside wall of the shell. The polymer bonds to the inside wall of the shell upon the polymer being cured.

Description

THREE DIMENSIONAL LAMINATE BEAM STRUCTURE BACKGROUND OF THE INVENTION
For various applications, such as in the automotive industry, it is desirable to reinforce a structural section. One approach has been to use a polymer structural foam material for such reinforcement. In some of these applications, however, because of the location or geometry of the part being reinforced, it is difficult to accomplish the intended reinforcement.
Hydra-formed metal sections, for example, may have curved three-dimensional geometry. As a result, reinforcing the section or component is very difficult because the location of the hydra-formed section that is critical and decides the overall performance of the component, is often the section located at a major discontinuity "notch" or curvature . SUMMARY OF THE INVENTION
An object of this invention is to provide a reinforced beam of curved geometry.
A further object of this invention is to provide techniques for reinforcing such a beam.
In accordance with this invention the beam is a hollow structure. A pre-molded foam core is inserted into the hollow structure spaced from at least one inside wall of the hollow structure. A polymer is pumped in and around the foam core insert so that after curing the polymer bonds to the inside wall of the structure.
In a preferred practice of the invention the structure is a hydra-formed metal section, such as a vehicle control arm assembly. The pre-shaped foam insert is preferably made of a lightweight material to minimize the weight of the final laminate beam formed by the invention. BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a perspective view of a laminated control arm assembly beam in accordance with this invention; and
Figure 2 is a cross-sectional view taken through Figure 1 along the line 2-2. DETAILED DESCRIPTION OF THE INVENTION
The present invention is particularly useful for reinforcing hollow sections or structures, which are of curved geometry and/or located at locations, which are relatively inaccessible.
In the preferred practice of the invention the hollow structure is a metal section, such as a hydra-formed metal section with curved three-dimensional geometry. An example of such section is a control arm assembly, wherein it is desired to reinforce the control arm beam. For such hydra- formed section the critical portion which requires reinforcement in order to maximize the overall performance of the component is often the portion at a major section discontinuity "notch" or curvature. Figure 1, for example, illustrates an automotive control arm assembly beam 10 made of a hydra-formed metal shell 12 of conventional size and shape and structure such as including through holes 14 and end walls 16. As can be seen the shell 12 has a three dimensional geometry which is non-uniform from end wall to end wall and which is curved.
Because of its geometry, it is very difficult to reinforce a control arm beam 10 by conventional practices.
In accordance with this invention a preformed foam core 18 is inserted into the hollow or cavity of shell 12. Core 18 is spaced away from at least one inside wall of the hollow shell 12 and is shaped to extend along at least one side of the shell . Core 18 functions to locate a reinforcing polymer 20 within the hollow shell so that after curing the polymer will bond to and reinforce the inside wall of the shell.
Core or insert 18 is made of a lightweight pre-shaped or preformed material such as urethane, phenolic or expanded polystyrene. The polymer 20 would be pumped in and around the foam core 18 so as to be located in the space between core insert 18 and the inner wall of shell 12. Polymer 20 is then cured such as being heat cured or ambient temperature cured. Upon curing polymer 20 is bonded to the inner wall of shell 12 and to foam core 18 to function as a structural foam. The polymer or structural foam may be, but is not necessarily an expandable foam.
Examples of suitable foam material are found in my U.S. Patent No. 5,575,526 and in co-pending application Serial No. 09/103,031 filed June 23, 1998, all of the details of that patent and application are incorporated herein by reference thereto .
The curing of the polymer could be accomplished in any suitable manner. For example, where the shell 12 is a vehicle component, the polymer could be heat cured in an oven such as an e-coat oven during the manufacturing of the vehicle. Alternatively, the polymer could be cured at ambient temperatures such as, for example, about 77*F. The foam core insert 18 may be pre-shaped in a geometry which generally conforms to the inner surface of shell 12 thereby minimizing the amount of polymer material required to fill the remaining open space within shell 12. Alternatively, core insert 18 may be of uniform cross- sectional shape throughout all or most of its length to simplify the structure of the core insert, but which would result in a greater amount of open space. The foam core insert 18 thus comprises a three-dimensional or essentially two dimensional molded pre-formed part which occupies some of the volume or space within shell 12 and provides a substrate for the polymer 20 which is pumped into the shell 12.
The invention thus results in a three-dimensional laminate beam, which is formed by pumping the polymer around the pre-molded foam core. This is the only means necessary to reinforce such a hydra-formed metal section.

Claims

IN THE CLAIMS ;
1. A three dimensional laminate beam structure comprising an outer shell having inside walls and an open space between said walls, at least a portion of said shell being curved, a core insert mounted within said shell spaced from at least one of said inside walls, a reinforcing polymer within said shell, and said polymer being disposed against said core insert and bonded to said inside wall of said shell.
2. The beam of claim 1 wherein said core insert is made of a lightweight foam.
3. The beam of claim 2 wherein said polymer is pumped in and around said foam core insert.
4. The beam of claim 3 wherein said shell is made of a metal material being of non-uniform shape along its length.
5. The beam of claim 4 wherein said shell is a hydra-formed metal section.
6. The beam of claim 5 wherein said beam comprises a vehicle control arm assembly.
7. The beam of claim 3 wherein said polymer is an expandable structural foam.
8. The beam of claim 3 wherein said polymer is a non- expandable structural foam.
9. The beam of claim 3 wherein said polymer is heat curable.
10. The beam of claim 3 wherein said polymer is ambient temperature curable.
11. A method of forming a three-dimensional laminate beam comprising the steps of inserting a pre-formed core insert within a hollow shell with the insert spaced from at least one inside wall of the shell and with the shell being of curved shape, pumping a reinforcing polymer in and around the core insert, and curing the polymer to cause the polymer to bond to the inside wall of the shell.
12. The method of claim 11 including pre-molding the core insert from a lightweight foam material.
13. The method of claim 12 wherein the shell is made of a hydra-formed metal section of non-uniform shape along its length.
14. The method of claim 12 wherein the resulting beam is a vehicle control arm assembly.
15. The method of claim 13 wherein the resulting beam is a vehicle component.
16. The method of claim 15 wherein the polymer is heat cured.
17. The method of claim 15 wherein the polymer expands upon curing.
18. The method of claim 15 wherein the polymer is cured at ambient temperatures.
EP99943755A 1998-09-09 1999-09-02 Three dimensional laminate beam structure Withdrawn EP1109713A4 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US14997898A 1998-09-09 1998-09-09
US149978 1998-09-09
PCT/US1999/018832 WO2000013958A1 (en) 1998-09-09 1999-09-02 Three dimensional laminate beam structure

Publications (2)

Publication Number Publication Date
EP1109713A1 true EP1109713A1 (en) 2001-06-27
EP1109713A4 EP1109713A4 (en) 2003-02-12

Family

ID=22532613

Family Applications (1)

Application Number Title Priority Date Filing Date
EP99943755A Withdrawn EP1109713A4 (en) 1998-09-09 1999-09-02 Three dimensional laminate beam structure

Country Status (5)

Country Link
EP (1) EP1109713A4 (en)
JP (1) JP2002524339A (en)
CA (1) CA2342666A1 (en)
TR (1) TR200100648T2 (en)
WO (1) WO2000013958A1 (en)

Families Citing this family (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6321793B1 (en) * 2000-06-12 2001-11-27 L&L Products Bladder system for reinforcing a portion of a longitudinal structure
DE10112688A1 (en) * 2001-03-16 2002-09-26 Sika Ag, Vormals Kaspar Winkler & Co Reinforcement for vehicle bodywork pillars, and other hollow components, is a strengthening skeleton of injection molded heat-resistant plastics with support surfaces held by lateral ribs and longitudinal bars
US6682818B2 (en) 2001-08-24 2004-01-27 L&L Products, Inc. Paintable material
US6793274B2 (en) * 2001-11-14 2004-09-21 L&L Products, Inc. Automotive rail/frame energy management system
US20040115414A1 (en) * 2002-03-15 2004-06-17 Joseph Wycech Method for stiffening or reinforcing a member in a cost effective manner and a member which is made in accordance with the method
US7077460B2 (en) * 2002-04-30 2006-07-18 L&L Products, Inc. Reinforcement system utilizing a hollow carrier
US8475694B2 (en) 2005-10-25 2013-07-02 Zephyros, Inc. Shaped expandable material
GB201016530D0 (en) 2010-09-30 2010-11-17 Zephyros Inc Improvements in or relating to adhesives

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE4203460A1 (en) * 1991-02-20 1992-08-27 Volkswagen Ag Prodn. of impact-absorbing beam for e.g. car - by placing lightweight core with foaming cover in metal sections, welding them, and hot dip coating to foam up cover, and fill remaining spaces
DE19706309A1 (en) * 1996-02-19 1997-08-21 Tokai Rubber Ind Ltd Foam-filling hollow vehicle body member to reduce internal wind noise
FR2749263A1 (en) * 1996-05-31 1997-12-05 Renault Reinforced structure element for automobiles

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4722563A (en) * 1984-06-25 1988-02-02 Michael Ladney Vehicle bumper
US5575526A (en) * 1994-05-19 1996-11-19 Novamax Technologies, Inc. Composite laminate beam for radiator support
US5806919A (en) * 1996-11-04 1998-09-15 General Motors Corporation Low density-high density insert reinforced structural joints

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE4203460A1 (en) * 1991-02-20 1992-08-27 Volkswagen Ag Prodn. of impact-absorbing beam for e.g. car - by placing lightweight core with foaming cover in metal sections, welding them, and hot dip coating to foam up cover, and fill remaining spaces
DE19706309A1 (en) * 1996-02-19 1997-08-21 Tokai Rubber Ind Ltd Foam-filling hollow vehicle body member to reduce internal wind noise
FR2749263A1 (en) * 1996-05-31 1997-12-05 Renault Reinforced structure element for automobiles

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See also references of WO0013958A1 *

Also Published As

Publication number Publication date
EP1109713A4 (en) 2003-02-12
JP2002524339A (en) 2002-08-06
WO2000013958A1 (en) 2000-03-16
TR200100648T2 (en) 2001-06-21
CA2342666A1 (en) 2000-03-16

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