GB2131737A

GB2131737A - Shaped bodies and method for their production

Info

Publication number: GB2131737A
Application number: GB08328088A
Authority: GB
Inventors: Arturo Macchi; Dario Abrami
Original assignee: MACCHI INTERNATIONAL SpA
Current assignee: MACCHI INTERNATIONAL SpA
Priority date: 1982-10-21
Filing date: 1983-10-20
Publication date: 1984-06-27
Also published as: DE3338160A1; PT77536A; FR2534847A1; GB8328088D0; SE8305761L; ES8500151A1; ES526587A0; SE8305761D0; PT77536B

Abstract

A method of producing shaped bodies, in particular bumpers for vehicles in which one or more filler elements (B) are formed in expanded foam material and said filler elements are located in a mold to mold a resistant involucre (A) for example of high density polymerizable polyurethane material capable of incorporating and firmly retaining said filler. Before being introduced into the mold, the filler is provided with a layer of fibrous reinforcing material, preferably of fiber-glass. <IMAGE>

Description

SPECIFICATION Shaped bodies and method for their production The present invention relates to a method of producing shaped bodies for vehicles and to shaped bodies such as for example bumpers panels and spoilers.

An object of the invention is to produce parts for vehicles, such as bumpers, spoilers arm rests and seat bottoms for motor vehicles.

Another object of the invention is to simplify and improve the production of the resistant structure of bodies in relation to their specific end use, especially, but not exclusively for their advantageous end use as bumpers for vehicles.

According to the present invention there is provided a method of producing shaped bodies for vehicles which bodies have a resistant supporting structure and may be anchored to the vehicle, the method comprising incorporating a filler, in the molding phase, into the resistant supporting structure at least part of the walls of which structure are made of flexible material, said filler consisting, at least in part, of an elastically yielding material.

According to a further aspect of the invention there is provided a shaped body for vehicle structures, comprising a resistant supporting structure for securing to the chassis of a vehicle, wherein the resistant supporting structure has at least one seat housing and retaining securely a yielding filler element, at least a part of the walls of the supporting structure being of a flexible material.

According to the present invention there is also provided a shaped body for a vehicle which body has a resistant supporting structure and may be anchored to the vehicle, wherein a filler consisting at least in part of elastic yielding material is incorporated into the resistant supporting structure, at least a part of the walls of which structure are made of flexible material.

In one embodiment of the present invention, the supporting structure cavity is at least partly lined with one or more layers of suitable reinforcing material, for example, fibrous material, to form, within said structure, reinforced zones of suitable characteristics particularly adapted to withstand shock.

Further, the shaped body preferably consists of a supporting structure of resistant material for securing to the frame of a vehicle; and in particular, this body is characterized in that the supporting structure is provided with means to secure it to the vehicle's structure and by at least one cavity capable of incorporating an elasticity yielding filler body.

If the shaped body is to be used as for example, a bumper, iits supporting structure will be provided with at least one air tight chamber incorporating one or more filler bodies, while it is provided, in its lower part, with securing means for engaging with the different parts of the vehicle's frame and hence adapted to transmit the impact or shock force over a wide surface.

Advantageously, the filling bodies are made of expanded foam resin such as, for example, low density polyurethane resin and may be provided with a coating consisting advantageously of fiberglass anchored superficially to the structure of said bodies.

Embodiments of the present invention will now be described, by way of example, with reference to the accompanying drawings, which illustrate two different types of shaped bodies which may be produced in accordance with the invention, and in which: Figure 1 is the partial top view of a bumper produced according to an embodiment of the invention; Figure 2 is a cross sectional view of the bumper shown in Figure 1; Figures 3 and 4, are cross sectional views similar to Figure 2, of other embodiments of a bumper; Figures 5, 6 and 7 are transverse cross sectional views of a further embodiment of a bumper produced in accordance with the invention; Figure 8 is a view taken on a horizontal cross section of Figure 6; and Figure 9 is the transversal sectional view of a spoiler for monitoring on the rear part of a vehicle to deviate the wind, produced in accordance with the invention.

Figures 1 and 2 show a bumper provided with a housing or shell A of desired characteristics and having one or more chambers 10. In Figure 2, these chambers 10 are open to the rear, while their front vertical walls 12 may be provided with reinforcing ribs, externally and/or internally.

Obviously, when the ribs 20 are internal, they project into chambers 10 and can be utilized for the purposes described hereinafter. Housing A has a longitudinal flap 34 on its bottom portion which adapts itself to and attaches to the rear part of the vehicle's body; the flap may extend beyond the extremity of the bumper with complementary tracts 35 cooperating with the lower ends of the side walls of the vehicle.

Housing A firmly contains one or more padding or filler elements each of which is of expanded resin foam, such as for example, low density polyurethane resin foam.

Again, with reference to Figure 2, a lining layer C is interposed between the internal walls of housing A and filler B which is of suitable, prevalently fibrous material suited to providing strengthening means.

Layer C may, for example, be made of fiber glass which may possibly be treated with a suitable resin to ensure its adherence and anchorage with the materials forming housing A and filler body B. The thickness of layer C may vary conveniently depending on the specific requirements to be met, especially when this layer is to delimit the reinforced resistant zones in bumpers.

Embodiments of the method for producing a shaped body according to the invention, such as the bumper shown in Figures 1 and 2, will now be described.

Filler B is produced in known manner by using a mold to reproduce approximately the chamber or chambers 10 of housing A. Naturally, the shape of the or each filler element B must be smaller or reduced with respect to its respective chamber 10 and its shape need not necessarily reproduce exactly the profile of chambers 10 of housing A.

This constitutes a considerable advantage afforded by the invention, without prejudice to its final objects.

The filler material B may be provided with imprints and or reliefs of the desired size such as ledge or groove 40 (Figure 2), in the rear part of the bumper, which houses a bar D secured to the vehicle chassis to support the bumper and at the same time react to impacts to which it may be subjected in actual use.

Once the filler material B is completed, the reinforcing layer C is applied to it, as will be explained below.

In the embodiment of Figure 2, layer C has been applied so as to envelope the filler element B and also to form the rear wall 16 of the bumper which is continuous with the rear face of longitudinal wing 34 for adherence to and cooperation with the vehicle body wall.

To ensure adhesion between filler B and supporting structure A, if a reinforcing layer C is interposed between these parts, a fluid resin is also applied on the latter. During the stamping phase of supporting structure A the fluid resin ensures incorporation and adhesion of the different parts with each other.

Once the filler element B has been completed, it is placed in the cavity of the mold which reproduces, in the negative, the shape of the supporting structure A. The mold is then closed and a resin of suitable type is injected into the interspace which has been delimited, by suitable spacers in this cavity, between the walls of said cavity and filler element B. Housing A is thus formed, having walls of suitable thickness.

A high density polymerizable polyurethane resin is used for this operation; said resin is particularly suitable in the case of bumpers because of its characteristics of elasticity and resistance to shock stresses.

In addition to filling the interspace previously mentioned, the resin also penetrates into the surface of filler B and, in the presence of reinforcing layer C inbibes this and forms together with filler B a single monolithic body able to meet satisfactorily the end use requirements.

In the case of bumpers, the shock of impact is felt first by wall 12 of housing A and is then transmitted, through reinforcing layer C to filler B, which, due to its particular characteristics and properties absorbs the shock. In fact, the impact action extends to and involves a wide zone of the filler body and is transferred in dampened distributed form to the chassis of the vehicle.

Once the impact action has dissipated, the parts of the bumper return to their initial status because of the different elasticity characteristics of the three layers of material involved in the impact.

A reinforcing layer C consisting, as stated above, of a fibrous material, can be placed beforehand in the forming mold for the housing A so that this layer will be more or less incorporated into and retained by the material forming said housing A.

Alternatively, and in like manner, the fibrous material for forming the reinforcing layer C can be arranged in and caused to adhere to the walls of the mold for the filler element B prior to introducing the polyurethane resin which, through expansion and solidification will incorporate and securely retain the reinforcing layer and also anchor itself superficially to said filler B.

Figure 3 is a transverse section of another embodiment of a bumper according to the invention.

In this figure, parts equivalent to those shown in Figures 1 and 2 are identified by the same reference symbols. In this embodiment, rear wall 16a of housing A is provided with a plurality of parallel horizontal fins 42, the ends of which engage with the rear (or front) wall of the vehicle's body to retain the bumper elastically.

In the embodiment shown in Figure 4, which is similar to that of Figure 3, the surfaces of filler B engage directly and incorporate to a certain depth, the material of housing A. Longitudinal parallel slots of a desired length are provided in the rear part of filler B.

The resin associated with the housing A, during its molding, forms fins 44 which are embedded in said filler to create in the structure of the bumpers, zones of the desired elasticity and resistance to shock.

Figures 5 to 8 show a further embodiment of a bumper for vehicles. In this embodiment, housing A is provided, substantially along its entire length with one or more practically air tight chambers 50, the walls 52, 54, 56, 58 of which form a monolithic closed structure. Vertical walls 52 and 56 of said chambers 50 may differ in thickness from horizontal walls 54 and 58 in order to withstand and react to the mechanical stresses and shock to which the bumpers will be subjected during use.

For these purposes, vertical walls 52 and 56 are provided, at convenient positions with ribs 60 and 62 extending horizontally along their internal surfaces.

In the case of Figure 7 and the ends of the ribs are interconnected to form fins 60-62 which delimit within the closed chamber 10 two or more overlapped chambers 64 and 66 which are also closed and are separated from each other.

The production of a shaped housing A is effected as already described, and chambers 64 and 66 are stuffed with a filler of convenient consistency and elasticity in consideration of the need to withstand the dynamic stresses to which the bumper may be subjected. Shaped housing A, illustrated in Figures 6-8 is provided at convenient positions with areas of adequate thickness so as to form shaped cavities 78 at the points where opposite walls 52 and 56 are closest and penetrate each other. Again with reference to Figures 6 and 8, a set of one or more plates 70 are inserted and incorporated between the walls; said plates are provided with holes 72, whose function is to secure the bumper to the vehicle structure.

The embodiment of the bumper according to Figures 5 and 8 is produced as already described in relation to the bumpers of Figures 1 and 4.

As already stated, the bumpers produced according to this procedure provide all the advantages required and considered. Moreover, housing A for the bumper may have calibrated holes and apertures to place the interior in communication with the exterior and thus permit controlled passage of air.

The housing may be provided with, or incorporate parts for securing the bumper firmly to the vehicle chassis.

Again with reference to the procedure according to this invention, shaped bodies of other types may be produced, for other end uses, for example, parts of vehicles such as seats and lining panels.

Figure 9 shows one such further shaped body in the form of a stream-lined spoiler attached to the rear of the body of a motor vehicle. In this particular instance, the spoiler is provided with a housing A of the desired stream-lined shape and incorporates one or more shaped bodies or filler B.

The lower part of housing A terminates with a shaped wall 46 adaptable to the profile of the vehicle's body D. This wall retains securely, for example by incorporation of securing means such as bolts 48 to fasten the spoiler.

Claims

1. A method of producing shaped bodies for vehicles which bodies have a resistant supporting structure and may be anchored to the vehicle, the method comprising incorporating a filler, in the molding phase, into the resistant supporting structure at least part of the walls of which structure are made of flexible material, said filler consisting, at least in part, of an elastically yielding material.

2. A method according to claim 1 , further comprising interposing at least one layer of fibrous material between resistant supporting structure and filler in the molding phase.

3. A method according to claim 2, further comprising anchoring at least a part of the fibrous material layer to the filler and subsequently incorporating the whole into the resistant supporting structure in the molding phase of the latter.

4. A method according to claims 2 or 3, wherein a fluid resin is applied beforehand to the fibrous material to ensure adhesion and incorporation of said fibrous material with the filler and resistant supporting structure.

5. A method according to any one of claims 1 to 4, further comprising providing the resistant supporting structure with at least one closed air tight chamber the opposite walls of which cooperate, the rear with at least part of the vehicle frame, the front being an impact surface, while a filler body is retained in at least one of the resilient supporting structure chambers.

6. A method according to any one of claims 1 to 5, wherein a cellular structure resin is used to produce the filler element and a high density polyurethane resin to produce the resistant supporting system.

7. A method according to claim 6, wherein a low density expandable resin is used to produce the filler element.

8. A method according to any one of claims 1 to 7, wherein a layer of fiber-glass is interposed between the resistant supporting structure and the filler element.

9. A method of producing shaped bodies for vehicles substantially as herein described with reference to any one of the figures of the accompanying drawings.

10. A shaped body for vehicle structures comprising a resistant supporting structure for securing to the chassis of a vehicle, wherein the resistant supporting structure has at least one seat housing and retaining securely a yielding filler element, at least a part of the walls of the supporting structure being of a flexible material.

11. A shaped body for a vehicle which body has a resistant supporting structure and may be anchored to the vehicle, wherein a filler consisting at least in part of elastic yielding material is incorporated into the resistant supporting structure, at least a part of the walls of which structure are made of flexible material.

12. A body according to claim 10 or 11, wherein a fibrous material is interposed between the resistant supporting structure and the filler.

13. A body according to any one of claims 10 to 12, wherein the rear wall of the resistant supporting structure is provided with reinforcing ribs.

14. A body according to claim 13, wherein ribs are provided internal to the cavity for the filler and are anchored to the material of the filler.

1 5. A body according to any of claims 10 to 14, wherein the resistant supporting structure has at least one air tight chamber which houses an elastically yielding filling element capable of withstanding shock.

16. A body according to claim 15, wherein the walls of the or each chamber are provided with reinforcing ribs at least a part of which are elastically yielding and arranged inside said chamber so as to be horizontal when mounted to a vehicle.

17. A body according to claims 15 or 1 6, wherein a plurality of air tight chambers are provided and a part of said chambers overlap each other.

18. A body according to any of claims 1 5 to 1 7, wherein at least a part of the or each air tight chamber is filled with elastically yielding filler material.

19. A body according to any of claims 10 to 1 8, wherein the rear wall of the supporting structure is provided externally, with parallel fins for cooperating with the body of a vehicle.

20. A body according to any of claims 1 5 to 19, wherein said body is a bumper.

21. A shaped body for a vehicle substantially as herein described with reference to any of the Figures of the accompanying drawings.