MXPA98008576A - Reinforcement of lined sheet of slim sheet of me - Google Patents

Abstract

A reinforced wall comprises a rigid substrate having a reinforced sheet bonded or bonded to its inner surface. The reinforced sheet includes an outer thin sheet backing and an expandable polymer foam material bonded to the backing or backing of the thin sheet. The polymer foam binds intimately to the inner surface at the time of activation and expansion of the foam material

Description

REINFORCEMENT OF LAMINA LINED OF METAL SLIM SHEET DESCRIPTION OF THE INVENTION Background Structural members of high power and light weight were required in a number of applications. For example, in motor vehicles and aircraft, as well as in various devices such as household appliances and the like. In the past, a number of structural materials were proposed as reinforcing agents, such as structural members, such as lightweight exotic alloys. However, in most applications, the mass reduction must be balanced against the cost of the product to the consumer. Thus, there is a need to provide strength without significantly increasing material and production costs. Furthermore, reinforcement techniques that can be adapted to the existing geometries of structural parts are needed, avoiding any requirement for fundamental design changes.

It would be desirable to provide a structural member that can generally be considered as a wall with some form of reinforcement. While these forms of reinforcements could have quantity of alloys, it would be particularly desirable to provide these reinforcements for the vehicle door panels.

A typical motor vehicle door includes an outer cover or panel made of aluminum or thin steel. The outer panel is attached to the structural members and together with an interior door panel defines a space or cavity in which a movable window is retracted. In addition to the movable window, a number of latch fastener supports and window actuators are located in this door space.

Due to the area of the outer panel and its thickness, a phenomenon such as "packaged oil" can occur. The term packaged oil refers to those of the type in which the bottom of the can has a reciprocating flexion p-na distributing the oil. This movement c n frecaen.-i =. It causes a crisp noise when the metal flexes. Applied to a panel of an exterior door, the packaged oil refers to the tendency of the door panel to flex from its desired position (often typically bent) to a second undesired position in which the outer panel is deformed or bending * - internally towards the interior door panel. This movement can occur in response to lic-r operations? on the outer panel as the weight of an individual inclination against the vehicle.

Although the packaged oil may be momentary in the panel that returns immediately to its original configuration, it may be permanent and, moreover, may cause a crease in the panel coating. As will be understood by those skilled in the art, folds of this type must be removed in a sheet metal shop or the like and the panel is required to be repainted.

While a number of lateral impact beams are known, these beams focus on the structural integrity of the tiotootoi vehicle in a crash and not on the problem of the packaged oil - for example, a side impact beam. A vehicle door was proposed, which comprises a metal member in the form of an open channel having a longitudinal cavity which is filled with a core of material based on thermoplastic or thermoset resin. The soul is placed in the center of the bath section. The soul does not adhere to the sides of the bath. The core may include hollow glass micro-spheres in order to increase the density and thus the weight.

Although large fill volumes of a door cavity can avoid packaged oil, this access will also significantly increase the mass and thus the weight, which of course is an undesirable feature. In addition, large volumes of foam contribute significantly to the cost. Finally, a large foam core often causes an undesirable thermal release. And although increasing the gauge of the metal of the door panel or adding the localized thick metal reinforcements will increase the rigidity, as the thickness of the metal increases the weight increases.

Accordingly, there is a need for a lightweight door panel stiffener that is economical to produce and install. This stiffener is desirable for door panels in general, even if it does not address the phenomenon of oil packaging.

Objectives of the Invention An object of this invention is to provide a reinforcement for a substrate or a wall.

A further objective of this invention is to provide a reinforcement having particular utility where the substrate or the wall is a vehicle door panel.

In accordance with this invention, a sheet metal foil reinforcement for a wall or substrate is made of a laminated polymer agglomerated to a thin sheet metal support. The polymer is preferably an expandable polymer foam that is placed against the inner surface of the wall or the substrate. At the time of polymer expansion, the foam of the polymer agglomerates to the inner surface of the substrate.

In one aspect the present invention provides a foamed sheet / foil reinforcement that substantially prevents or substantially reduces the oil packaging of the outer door panels. The foam sheet / thin sheet has a thin layer of thin metal sheet agglomerated to a layer of a consumable expandable resin. The foam sheet / thin metal sheet is corrugated along its length. The side of the sheet resin is agglomerated to the inner surface of the outer door panel in the center of the panel approximately. Fasteners can be used to hold the sheet in place. As the motor vehicle moves through a paint furnace, the resin expands through the activation of a blowing agent and agglomerates more evenly to the surface of the inner door. In one aspect, the recesses in the contact surface of the resin layer are filled by the expansion action of the foam. The reinforcement of the door panel significantly increases the stiffness of the door panel and eliminates or reduces the tendency of the panel to the oil container.

In another aspect, the present invention provides a method for reinforcing a door structure to reduce the oil container. A foil / foil sheet reinforcement is provided, which has a thin layer of thin metal foil agglomerated to a layer of a consumable expandable resin. As established, J foam sheet / thin metal sheet is corrugated along its length. The sheet is secured to the inner surface of the outer door panel at the center of the panel by approximately placing the side of the resin in contact with the inner surface of the panel. Fasteners can be used to hold the blade in place. In one practice of the invention, the resin is heated as the motor vehicle moves through a paint furnace, which expands the resin through the activation of a blowing agent. The expansion serves to agglomerate the sheet more evenly and secure the surface of the inner door. As established, the reinforcement of the door panel significantly increases the rigidity of the door panel and eliminates or reduces the tendency of the panel to the oil container. The present invention relates to variations of the practices described in the co-pending application of Series No. 08 / 675,173, filed on July 3, 1996, and also relates to the variations of the invention described in a co-pending application. , filed on May 7, 1998, entitled "COMPOSITE LAMINATED AUTOMOTIVE STRUCTURES". All the details of both co-pending applications are incorporated herein by reference. In this way it will not be necessary to repeat the different possible materials that various end uses or possible final applications for which the invention can be used, wherein these materials and end uses are mentioned in the two copending applications cited.

SUMMARY OF THE INVENTION This invention has for its object to provide a sheet reinforcement for a structure made of a stiff or generally rigid material. This structure has an internal surface that may be flat or may have some curvature. A particularly useful application of this invention is a reinforcement for the panels for vehicle doors. These panels for vehicle doors are conventionally made of a metal material such as steel. The invention can be practiced with other rigid or rigid materials, including other metals, plastics, etc.

In the general practice of the invention, the reinforcing sheet is of two layer constructions. An outer support layer is in the form of a thin sheet coating which could be made of metal, plastic, fiberglass, etc. Preferably aluminum is used for the lining of the thin metal sheet. The foam material is preferably a polymer that is expandable by means of thermal or chemical activation. The foam material can be provided in the form of sheet or sheet placed against and secured to the lining or liner of the metal foil. The foam material is also placed against the interior surface of the substrate. At the moment of the activation of the foam material the foam material expands and agglomerates intimately to the inner surface of the substrate. The lined sheet of the metal foil provides a reinforcement with stiffness and strength that increases at the moment of inertia, particularly of a flat or curved surface plate by placing the parent substrate and the high modulus sheet metal away from the neutral axis. The fact that the polymer foam expands and moves the metal sheet away from the substrate helps stiffen the substrate by increasing the depth of the reinforcement section. The thin sheet liner acts as a restricted layer to ensure that the polymer is homogeneous throughout the thickness after expansion and cure, BRIEF DESCRIPTION OF THE DRAWINGS In order to provide a better understanding of this invention, a detailed description thereof is given below in conjunction with the accompanying drawings, and in which: Figure 1 is a side elevational view of the interior surface of a vehicle door panel with a reinforcement area in accordance with this invention; Figure 2 is a cross sectional view taken through to Figure 1 along line 2-2.

Figures 3-4 are views similar to Figure 2 of the alternative forms of the reinforcement in accordance with this invention; Figure 5 is a view similar to Figure 1 of a further practice of this invention; Figure 6 is a perspective view showing the foam in the sheet in unexpanded form; Figure 7 is a cross sectional view taken through Figure 6 along line 7-7; Figure 8 is a cross sectional view taken through Figure 5 along line 8-8 when the sheet is in the manner shown in Figures 6-7, and; Figure 9 is a view similar to Figure 8 showing the sheet when the foam is in its expanded state.

Preferred Modalities of the Invention Figures 1-2 illustrate a practice of the invention. As shown therein, the invention is used to reinforce a vehicle door 10. As also shown, a two-layer logo 12 is used for reinforcement. The sheet 12 may be placed on a selected portion or portions of the interior surface of the door panel or substrate 10 or may reinforce the entire interior surface. Preferably the sheet 12 is located in the central area of the door. When the substrate is a door panel, sufficient clearance must be provided to accommodate conventional components such as the movable window and its latch fasteners and actuators.

As best shown in Figure 2, the sheet 12 includes a coating of the outer thin metal sheet or backing 14 and an intermediate foam polymer 16. The foam polymer 15 is preferably made in an insulated laminate form and from this Mode supported by the liner or reverse m eto thin sheet 14. The foam polymer 16 would be placed directly against the inner surface 18 of the substrate 10. Figure 2 illustrates the sheet 12 where the foam is in its unexpanded form. However, therefore the foam polymer would be activated in such a way that it would expand and move the thin sheet forum 14 further away from the parent substrate 10. Where the substrate 10 is an automotive part or a door panel, the preferred way Activation is the thermal activation, so that you can make use of several heating steps such as e-coating used in the manufacture of vehicles without requiring any special or additional heating step. However, it should be understood that the invention can be practiced with other types of foam material activated in other ways, as is the chemical activation known in the art. Preferably, the laminated polymer is an epoxy of the types described in the co-pending applications mentioned above. The unexpanded epoxy would have a thickness of 0.040 - 0.200 inches. The liner of the thin metal sheet 14 is preferably of aluminum foil 0.001-0.006 inches thick. In this preferred practice of the invention, the polymer is cured in a paint furnace and agglomerates to the inner surface 18 of this base substrate 10 as it is agglomerated to the backing of the thin sheet. While aluminum is the preferred material for thin sheet lining, other materials can be used like metals, including aluminum, as well as plastics, glass fibers, etc. Aluminum is the preferred material because it has a high modulus which is particularly advantageous for reinforcement.

One sale of the invention is that the thin sheet lined sheet can be molded into sections by suitable known techniques such as stamping and rolling.

The sheet will retain its shape due to the rigidity and light weight of the thin sheet metal lining. The ability to form in a particular shape allows the sheet to be used where it is not of uniform thickness. The Figure 2, for example, illustrates the uniform thickness. However, Figures 3-4 show the variations that could be incorporated, which would require a non-uniform thickness. As shown in Figure 3, the liner of the metal foil 14 includes an outer channel section 20 that forms a projection or flange in combination with the extended portion 22 of the foam polymer. similarly, Figure 4 shows the extensions or flanges of the end 24 for the skin of the thin sheet and the end flanges 26 for the foam polymer in combination with a central extension 28 of the skin of the thin sheet and a central extension 30 of the polymer. The panel 10 may include a projection 32. The provisions of these outer extensions result in flanged sections that offer even more rigidity to the panel than a uniform or completely flat and / or laminated panel, due to the increase in section and the redidstribution of the reinforcement of the laminated sheet of the thin sheet away from the neutral axis of the panel. Thus, Figures 3-4 illustrate the sheet to include the rigid flanges while Figure 4 additionally includes the rigid edge tabs.

Figure 2 illustrates the door panel 10 having a hollow curve configuration, while Figures 3-4 show the planar panel 10.

Figures 5-9 illustrate a variation of the invention wherein the sheet 36 is structured to address the phenomenon of the oil package. As shown in this, the liner of the thin sheet 38 and the polymer foam 40 would be of the same thickness generally as in the previous embodiments. However, a difference of the sheet 36 is that it is formed in a corrugated or corrugated form having alternating hollows and mounds. The sheet 36 could be mounted to the door panel to the substrate 10 in the manner illustrated in Figures 2-4, where it is simply placed against the desired portion of the interior surface 18 of the substrate 10. The characteristics of the material of foam are sufficient to initially mount the blade in place. The assembly becomes permanent at the time of curing the polymer, when it expands and is intimately bonded to the inner surface 18 of the panel 10. However, if desired several practices of the invention (including Figures 2-4) can incorporate a support bracket such as a U-shaped frame 42 that would be secured to the surface 18 of the substrate 10. The sheet 36 could then be placed in the holder bracket as shown in Figure 8. The initial contact of the polymer against the panel 10 temporarily holds sheet 36 in place. At the time of expansion of the foam material 40, the foam would be intimately bonded to the inner surface 18, while the skin of the thin sheet 38 would move outward from the inner surface 18 as illustrated in Figure 9.

As shown in Figure 9, after the activation or expansion of the foam 40, the holes on the side of the foam 40 placed towards the inner surface 19 are filled by expansion of the foam. However, the lining of the corrugated thin sheet 38 retains its shape and correspondingly to the outer surface of the foam 40 is corrugated in a similar manner. Preferably, the sheet 36 would be located approximately at the center of the lining of the corrugated thin sheet 38, retaining its shape and "correspondingly to the outer surface of the foam 40 is corrugated in a similar manner. Preferably the sheet 36 would be located approximately at the center of the substrate 10 when used as a door panel. The significant increase in stiffness of the door panel eliminates or reduces the tendency of the panel to exhibit the phenomenon of the oil container.

Claims (23)

1. A reinforced wall comprising a rigid substrate having an inner surface, a reinforcing sheet attached to the inner surface; the reinforcing sheet comprises an outer support made of a thin sheet material, an expandable polymer foam material bonded to the support of the thin sheet and placed against the inner surface of the substrate and the foam material is agglomerated to the inner surface at the time of expansion of the foam material.

2. The reinforced wall of claim 1, wherein the substrate and the interior surface are flat.

3. The reinforced wall of claim 2, wherein the substrate and the inner surface are of a hollow, curved configuration.

4. The reinforced wall of claim 1, wherein the foam of the polymer is expandable by means of heat.

5. The reinforced wall of claim 1 wherein the material of the thin sheet of metal.

6. The reinforced wall of claim 5 wherein the substrate is a part of the vehicle.

7. The reinforced wall of claim 5 wherein the substrate is a panel of the vehicle door.

8. The reinforced wall of claim 7, wherein the foam material has a thickness before expansion of 0.004-0.200 inches.

9. The reinforced wall of claim 8, wherein the liner of the thin sheet has a thickness of 0.001 - 0.006 inches.

10. The reinforced wall of claim 9 wherein the liner of the thin sheet is made of aluminum.

11. The reinforced liner of claim 7 wherein the sheet has outer edges and the sheet includes a rigid flange located generally at the center of the outer edges.

12. The reinforced wall according to claim 11, wherein the sheet includes edge flanges that extend outwardly.

13. The reinforced wall according to claim 7, wherein the sheet has a corrugated shape.

14. The reinforced wall according to claim 7 including a support bracket mounted to the inner surface of the substrate and the sheet is placed in the support bracket.

15. The reinforced wall according to claim 1, wherein the sheet is of a non-planar structure.

16. The reinforced wall according to claim 15 wherein the sheet is corrugated.

17. The reinforced wall according to claim 15, wherein the sheet includes outer edges and a rigid flange which is generally located centrally between the outer edges.

18. The reinforced wall according to claim 17, wherein the sheet includes edge flanges that extend outwardly.

19. The reinforced wall according to claim 16, including a support bracket mounted on the inner surface of the substrate, and the sheet is in the support bracket.

20. A method of reinforcing a wall in the form of a rigid substrate having an inner surface that provides a reinforcing sheet in the form of an outer thin sheet liner and a expandable foam material secured to the liner; placing the expandable foam material against the inner surface of the substrate with the liner of the remote thin sheet to the inner liner of the substrate and activating the expandable foam material to intimately bond the foam material with the inner surface of the substrate and move it to the lining of the substrate. the thin sheet farther from the inner surface.

21. The method of claim 20, wherein the substrate is a vehicle door panel, and the foam material is activated in the expansion by passing the door panel and sheet through a heating oven.

22. The method of claim 21, wherein the sheet is of a non-planar shape, and whereby the portions of the sheet are placed farther from the inner surface of the substrate than from other portions of the sheet.

23. The method of claim 22, wherein the sheet is of a corrugated shape.