GB2042428A

GB2042428A - Reinforcing panel structure

Info

Publication number: GB2042428A
Application number: GB8003428A
Authority: GB
Original assignee: McCord Corp
Current assignee: McCord Corp
Priority date: 1979-02-22
Filing date: 1980-02-01
Publication date: 1980-09-24
Also published as: JPS55114558A; FR2449523A1; AU5440780A; IT8047690A0; DE3003358A1

Abstract

A reinforcing panel structure to be utilised in a vehicle body includes a first plurality of spaced parallel ribs 12 and a second plurality of spaced parallel ribs 14 extending perpendicularly to the first plurality of ribs. Each of the ribs has top and bottom parallel edges 16, 18 interconnected by sides with the sides of all the ribs being generally parallel to one another. Each of the ribs has an integral sheet 20, 22 extending transversely from opposite edges thereof with the sheet extending from one edge of each rib extending in one direction only and the sheet extending from the opposite edge extending only in the opposite direction the sheets define openings 24 therein. A mould assembly is disclosed for making the panel including female and male moulds with each mould having a base surface with four- sided projections extending upwardly from the base surface. <IMAGE>

Description

SPECIFICATION Reinforcing panel structure and mould assembly for making the reinforcing panel structure TECHNICAL FIELD The invention relates to a reinforcing panel preferably well-suited for reinforcing plastic sheets such as those utilised in automatic vehicle body components and to a mould for making such a reinforcing panel.

PRIOR ART There are various reinforcing panels known to the prior art; however, because of their construction they usually have an inherent weakness in certain directions and/or have localised areas of high stress. Other reinforcing panels because of their structure or configuration have high weight to strengthen ratios and are, therefore, unsuitable for specified uses.

STATEMENT OF INVENTION AND ADVAN TAG ES The invention provides a reinforcing panel structure having a first plurality of spaced continuous ribs intersected transversely by a second plurality of spaced continuous ribs with each of the ribs having top and bottom edges interconnected by sides and each of the ribs having an integral sheet extending transversely from each of the opposite edges with the sheet extending from one edge of each rib extending in one direction only with the sheet extending from the opposite edge extending only in the opposite direction and with the ribs and sheets being integral. Such a configuration provides a panel having a high section modulus.

Further according to the invention there is provided a mould assembly for moulding the reinforcing panel including male and female moulds with each of the moulds having a base surface with projections extending upwardly from the base surface to a raised surface with each of the projections on each mould being spaced from the next adjacent projection in the same mould in a first direction a distance equal to the dimentions of a projection of the opposite mould in that direction plus a predetermined dimension and which projections are spaced from the next adjacent projection in the same mould in a second direction transverse to the first direction a distance which is equal to the dimension of another projection of the opposite mould in that second direction plus a predetermined dimension so that the projections of the female mould are disposed in the spaces between the projectioiis of the male mould and are spaced from each other by the predetermined dimensions when the moulds are mated.

SPECIFIC DESCRIPTION Two embodiments of the invention will now be described by way of example only with reference to the accompanying illustrative drawings in which: Figure 1 is a fragmentary view of one face of a first embodiment of the invention being a reinforcing panel structure; Figure 2 is a cross-sectional view taken along the line 2-2 of Fig. 1; Figure 3 is a cross-sectional view taken along the line 3-3 of Fig. 1; Figure 4 is a fragmentary perspective view of the reinforcing panel structure of Figs. 1, 2 and 3; and Figure 5 is a fragmentary perspective view of a second embodiment of the invention being a mould assembly for making the panel structure of Figs. 1 to 4.

The first embodiment of a reinforcing panel structure according to the invention is generally shown as 10.

The panel 10 includes a first plurality of spaced parallel ribs 12. Also included is a second plurality of spaced parallel ribs 14 which extend transversely or perpendicularly to and intersect the first plurality of ribs 12 to define a plurality of four sided areas, i.e., quadrangles, rectangles or squares. As is clear from Fig. 1, each of the ribs 12 and 14 defines one side of two four sided areas and extends or is continuous through multiple four sided areas.

Each of the ribs 12 and 14 has top and bottom parallel edges as illustrated at 16 and 18 for the ribs 12 in Figs. 2, 3 and 4, it being appreciated that the transvsrse ribs 14 have similar top and bottom edges. The top and bottom edges 16 and 18 of each rib are connected by generally parallel sides. The sides of all of the ribs 12 and 14 are generally parallel to one another. The sides of the ribs 12 and 14 are generally parallel in the sense that they are disposed at a slight draft angle in the range of 1 to 3 , preferably 1.5 , to allow for mould or die draw. In other words, the sides are at an angle of approximately 1.5 in opposite directions on opposite sides of each rib to allow the part to be easily removed from the mould, although the sides of each rib are parallel.Such a slight angle is common in plastic moulding.

Each of the ribs 12 and 14 has an integral sheet extending transversely from each of the opposite edges thereof. The sheets 20 extending from the one or top edge 16 of each of the ribs 12 and 14 extends in one direction only from that top edge whereas the sheet 22 extending from the opposite or bottom edge 18 of each rib 12 and 14 extends only in the opposite direction. The sheets extending from intersecting ribs 12 and 14 are integral with one another. In other words, each of the ribs 12 and 14 has an integral sheet extending transversely from the opposite edges 16 and 18 thereof with the sheet 20 extending from the top edge 16 of each rib 12 and 14 extending in one direction only and with the sheet 22 at the opposite edge 18 of that rib 12 or 14 extending only in the opposite direction.

The ribs 12 and 14 define alternate four sided areas or quadrangles in transverse directions and the alternate four sided areas or quadrangles have integral sheets 20 interconnecting one extremity of the ribs 12 and 14 whereas the ribs 12 and 14 defining the remaining alternate four sided areas have integral sheets 22 interconnecting the opposite extremity of the ribs 12 and 14. In other words, the sheets 20 of alternate four side areas are disposed in a first plane and the sheets 22 of the remaining four side areas are disposed in a second plane which is spaced from and parallel to the first plane. Each of the four sided areas and the sheets 20 and 22 define a box-like cavity with the alternate box-like cavities opening in opposite directions as is best illustrated in Fig. 4. Additionally, the adjacent box-like cavities are separated by the thickness of the ribs 12 and 14.All of the ribs 12 and 14 are of equal thickness, i.e., of the same thickness.

Each of the sheets 20 and 22 interconnecting the edges 16 and 18 of the ribs 12 and 14 defining each four sided area has an opening 24 therethrough. Each of the openings 24 defines a quadrangle or area which is proportional to but smaller than the quadrangle or area defined by the adjacent ribs 12 and 14.

As will be appreciated fro the foregoing description in connection with the drawings, each of the ribs 12 and 14 are continuous and extend through a number of four sided areas or quadrangles. The holes or openings 24 in the oppositely disposed sheets are not necessary but they do reduce the weight of the panel without a proportional reduction in the strength of the panel. The importance of the ribs 12 and 14 extending continuously is to provide a high strength panel. The design of the panel is such that it enjoys a high section modulus as a maximum amount of material is disposed away from the neutral axis.

Turning to Fig. 5 there is disclosed a mould assembly for making the reinforcing panel structure of Figs. 1 to 4. The mould assembly is generally shown at 30 and includes a first or male mould generally indicated at 32 and a second or female mould generally indicated at 34. Each of the moulds 32 and 34 has a base surface 36 and 38 respectively. Four sided or quadrangular projections 40 and 42 extend upwardly from the base surfaces 36 and 38 respectively. The projections 40 extend upwardly to raised flat surfaces 44 and the projections 42 extend upwardly to raised flat surfaces 46.

Each of the projections 42 of the mould 34 is spaced from the next adjacent projection 42 in that mould 34 in a first direction D a distance dequal to the dimension a of the projection 42 in the direction D plus a predetermined dimension b plus b. In other words, each projection 42 is spaced from the next adjacent projection 42 a distance which is equal to its width a plus twice the thickness b of the ribs 12. In a similar fashion, each projection 42 is spaced from the next adjacent projection 42 in the mould 34 in a second direction Ewhich is perpendicular to the first direction a distance equal to the dimension of the projection 42 in the direction E plus a predetermined dimension which is b plus b, b being the thickness of the ribs 14 with the ribs 12 and 14 being of equal thickness.In a similar fashion, the projections 40 of the mould 32 are spaced from one another in exactly the same fashion. In a more general sense, each of the projections 40 and 42 of each mould 32 and 34 are spaced from the next adjacent projection in the same mould in a first direction D a distance equal to the dimension of a projection of the opposite mould in the first direction D plus a first predetermined distance and spaced from the next adjacent projection in the same mould in a second direction Etransverse to the first direction D a distance equal to the dimension of another projection of the opposite mould in the second direction E plus a predetermined dimension.Thus, the projections 42 of the female mould 34 are disposed in the spaces between the projections 40 of the male mould 32 and spaced from the projections 40 of the male mould by the predetermined dimensions when the female and male moulds are mated.

Thus, when the moulds 32 and 34 are disposed in mated relationship the projections 40 are disposed in the spaces between the projections 42. Also, when the moulds are mated, the raised surfaces 44 of the projections 40 are spaced from the base surface 38 of the mould 34 as are the raised surfaces 46 spaced from the base surface 36 of the mould 32 to thereby define the sheets 20 and 22.

Each of the projections 40 includes a four sided or rectangular embossment 48 on each of the raised surfaces 44 with each embossment 48 being smaller in area or dimension than the respective projection 40 and is proportional thereto and centred thereon. In a similar fashion each projection 42 includes a four side or rectangular raised embossment 50 on each of the raised surfaces 46 and which is smaller in dimension and proportional to the respective projection 42. The embossments 48 of the mould 32 engage the base surface 38 of the opposite mould 34 when the moulds are mated and, in a similar fashion, embossments 50 of the mould 34 engage the base surface 36 of the mould 32 when the moulds are mated. Clearly, the embossments 48 and 50 define the openings 24 in the panel structure 10.It will be noted that the projections 40 and 42 are identical in size and configuration and have side walls all of which are generally parallel to one another when the moulds are mated. The side walls of the projections 40 and 42 are spaced from adjacent side walls the thickness of the ribs 12 and 14 when the moulds are mated and the thickness or the spacing between the side walls of adjacent projections 40 and 42 when the moulds are mated are equal whereby the ribs 12 and 14 are of equal thickness. The side walls of the projections 40 and 42 are at an angle of between 1 and 3 from being perpendicular to the respective base surfaces 36 and 38 to allow the moulded panel to be easily removed from the moulds.Of course, each side wall of each projection 40 and 42 slants inwardly at the draft angle of 1 to 3 from the respective bases 36 and 38 upwardly to the respective surfaces 44 and 46.

The mould assembly 30 is particularly suitable for forming the panel 10 of plastic material in a reaction injection moulding process as the moulds 32 and 34 are easily cleaned between shots as there are no crevices or hard-to-get-at places in either mould and the projections 40 of the mould 32 are spaced from one another as are the projections 42 of the mould 34. It will be appreciated that the central portion of mould 32 is identical in configuration to the central portion of mould 34, differing only at the periphery for sealing off flange requirements.

A preferred embodiment has been illustrated and described, however, other embodiments and modifications are possible under the inventive concept. By way of example, the ribs 12 and 14 may vary in thickness and height from rib to rib in a given panel structure, and the top and bottom edges of the ribs 12 and 14 may not be parallel, as in a panel structure which is curved or arcuate only on one face. In a curved or arcuate panel, the top and bottom sheets may or may not be parallel. It will also be appreciated that the ribs may be continuous along a straight line or along a curved line and may intersect at angles other than right angles, i.e., other than perpendicular. Further, the openings 24 may be of shapes different than the shape of the projections, the importance of the openings being to reduce weight while retaining the desired structural strength or integrity of the panel. Thus, although a preferred#embodi- ment has been illustrated and described, modifications are available.

Claims

1. A reinforcing panel structure comprising; a first plurality of spaced continuous ribs, a second plurality of spaced continuous ribs extending transversely to the first plurality of ribs, each of the ribs having top and bottom edges interconnected by sides and having an integral sheet extending transversely from each of the opposite edges thereof with the sheet extending from one edge of each rib in one direction only and the sheet extending from the opposite edge extending only in the opposite direction with the sheets extending from intersecting ribs being integral.

2. A reinforcing panel structure comprising; a first plurality of spaced continuous ribs, a second plurality of spaced continuous ribs extending transversely to and intersecting said first plurality of ribs to define a plurality of four sided areas, each of said ribs defining one side of two of the four sided areas, each of the ribs having an integral sheet extending transversely from the opposite edges thereof with the sheet extending from one edge of each rib in one direction only and with the sheet at the opposite edge of that rib extending only in the opposite direction.

3. A reinforcing panel structure as claimed in Claim 2, in which the sheets of alternate four sided areas are disposed in a first plane and said sheets of the remaining four sided areas are disposed in a second plane which is spaced from said first plane.

4. A reinforcing panel structure as claimed in Claim 3, in which the first and second planes are parallel to one another.

5. A reinforcing panel structure as claimed in Claim 2, Claim 3 or Claim 4, in which each sheet interconnecting the edges of the ribs defining each four sided area has an opening therethrough.

6. A reinforcing panel structure as claimed in Claim 5, in which each of the said openings is proportional to the four sided area defined by the adjacent ribs.

7. A reinforcing panel structure as claimed in any one of Claims 2 to 6, in which each of the four sided areas and the sheets define a box-like cavity with alternate box-like cavities opening in opposite directions.

8. A reinforcing panel structure as claimed in Claim 7, in which adjacent box-like cavities are separated by the thickness of the ribs.

9. A reinforcing panel structure as claimed in Claim 8, in which the ribs are of equal thickness.

10. A reinforcing panel structure as claimed in any one of the preceding Claims, in which the first plurality of ribs are parallel and perpendicular to the second plurality of ribs.

11. A reinforcing panel structure as claimed in Claim 10, in which the ribs have side walls interconnecting the edges thereof with all of the side walls of the ribs being generally parallel.

12. A reinforcing panel structure comprising; a first plurality of spaced ribs, a second plurality of spaced ribs extending downwardly to and intersecting the first plurality of ribs to define a plurality of four sided areas, the ribs defining alternate four sided areas in transverse directions with said alternate four sided areas having integral sheets interconnecting one extremity of the ribs and the ribs defining the remaining alternate four sided areas having integral sheets interconnecting the opposite extremity of the ribs.

13. A mould assembly for making a reinforcing panel structure, the mould assembly comprisng; a female mould and a male mould each of said moulds having a base surface with four sided projections extending upwardly from the base surface to a raised surface, each of the projections of each mould being spaced from the next adjacent projections in the same mould in a first direction a distance equal to the dimension of a projection of the opposite mould in said first direction plus a first predetermined dimension and spaced from the next adjacent projection in the same mould in a second direction transverse to the first direction a distance equal to the dimension of another projection of the opposite mould in the second direction plus a second predetermined dimension, the projections of the female mould being disposed in the spaces between the projections of said male mould and spaced from the projections of the male mould by the predetermined dimensions when the female and male moulds are mated.

14. A mould assembly as claimed in Claim 13, in which the raised surface of the projections of the respective moulds are spaced from the base surface of the opposite mould when the moulds are mated.

15. A mould assembly as claimed in Claim 13 or Claim 14, including an embossment on each of the raised surfaces smaller in dimension than each respective projection.

16. A mould assembly as claimed in Claim 15, in which the embossments of the respective moulds engage the base surface of the opposite mould when said moulds are mated.

17. A mould assembly for making a reinforcing panel structure, said mould assembly comprising; a female mould and a male mould, each of said moulds having a base surface with four sided projections extending upwardly from the base surface to a raised surface, each of the projections of each mould being spaced from the next adjacent projection in that mould in a first direction a distance equal to the dimension of projection in said first direction plus a predetermined dimension and spaced from the next adjacent projection in that mould in a second direction transverse to the first direction a distance equal to the dimension of the projection in the second direction plus a predetermined dimension.

18. A mould assembly as claimed in Claim 17, in which said predetermined dimensions are equal.

19. A mould assembly as claimed in Claim 17, or Claim 18 in which the projections of the female mould are disposed in the spaces between said projections of the male mould and are spaced from the projections of the male mould by said predetermind dimensions when the female and male moulds are mated.

20. A mould assembly as claimed in Claim 19, in which the first and second directions are perpendicular.

21. A mould assembly as claimed in Claim 19 or Claim 20, in which the raised surface of the projections of the respective moulds are spaced from the base surface of the opposite mould when the moulds are mated.

22. A mould assembly as claimed in Claim 21 including an embossment on each of the raised surfaces smaller in dimension than each respective projection.

23. A mould assembly as claimed in Claim 2, in which the embossments of the respective moulds engage the base surface of the opposite mould when the moulds are mated.

24. A mould assembly as claimed in Claim 23, in which the first and second directions are perpendicular and the projections are identical and have side walls all of which are generally parallel to one another when said moulds are mated.

25. A mould assembly as claimed in Claim 24, in which the predetermined dimensions are equal.

26. A mould assembly substantially as herein described with reference to the accompanying illustrative drawings.

27. A reinforcing panel structure substantially as herein described with reference to the accompanying illustrative drawings.