WO1996005240A1 - Renforcement structurel - Google Patents

Renforcement structurel Download PDF

Info

Publication number
WO1996005240A1
WO1996005240A1 PCT/AU1995/000482 AU9500482W WO9605240A1 WO 1996005240 A1 WO1996005240 A1 WO 1996005240A1 AU 9500482 W AU9500482 W AU 9500482W WO 9605240 A1 WO9605240 A1 WO 9605240A1
Authority
WO
WIPO (PCT)
Prior art keywords
mixture
hollow
spheres
precursor mixture
specific gravity
Prior art date
Application number
PCT/AU1995/000482
Other languages
English (en)
Inventor
Terence Alan Russell
Original Assignee
Terence Alan Russell
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 Terence Alan Russell filed Critical Terence Alan Russell
Priority to AU31067/95A priority Critical patent/AU3106795A/en
Publication of WO1996005240A1 publication Critical patent/WO1996005240A1/fr

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/32—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof from compositions containing microballoons, e.g. syntactic foams
    • 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
    • B29C70/58—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising fillers only, e.g. particles, powder, beads, flakes, spheres
    • 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
    • B29C70/58—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising fillers only, e.g. particles, powder, beads, flakes, spheres
    • B29C70/66—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising fillers only, e.g. particles, powder, beads, flakes, spheres the filler comprising hollow constituents, e.g. syntactic foam
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K7/00—Use of ingredients characterised by shape
    • C08K7/22—Expanded, porous or hollow particles
    • C08K7/24—Expanded, porous or hollow particles inorganic
    • C08K7/28—Glass
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C3/00—Structural elongated elements designed for load-supporting
    • E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
    • E04C3/29—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces built-up from parts of different material, i.e. composite structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/16—Fillers
    • B29K2105/165—Hollow fillers, e.g. microballoons or expanded particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0089—Impact strength or toughness
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2363/00—Characterised by the use of epoxy resins; Derivatives of epoxy resins

Definitions

  • This invention is directed to means for improving the strength of hollow mechanical structures, and especially for improving the impact strength of structural members in motor vehicles.
  • the present invention can be seen as a method of strengthening portion of a hollow member comprising:
  • hollow micro-spheres having a shell of material different to that of said resin mix
  • the present invention can be seen as a method of strengthening portion of a hollow member comprising:
  • the invention can be seen as a method of strengthening portion of a hollow structural member comprising forming with a mould an insert which is shaped to fit the inside walls of the hollow member at its portion to be strengthened, and which insert is moulded using a precursor mixture as described above, permitting the mixture to set, and fastening the insert inside the hollow member to substantially fill the portion to be strengthened.
  • An additional curing period at an elevated temperature may be provided after the mixture is permitted to set.
  • the invention can be seen as a pumpable precursor mixture for a non-foaming structural void filler, said precursor mixture having a specific gravity between 0.4 and 0.7 and comprising a resin and hardener therefor, glass or plastic or ceramic hollow micro-spheres, and reinforcement fibres.
  • the precursor mixture contains 2 to 6 parts of fibre reinforcement of diameter from 5 to 25 ⁇ m and substantially evenly distributed within the precursor mixture. This may be achieved by evenly distributing the fibre reinforcement in at least one liquid component of the precursor mixture, before final mixing of the precursor mixture.
  • the reinforcement is glass fibres, although alternatives such as Kevlar aramid fibres, carbon fibres or boron fibres may be applicable. Other organic fibres such as hemp may also be used. A mixture of fibre types can be used. Preferably the fibres are in the form of relatively short chopped fibres rather than in long filamentary form, and have a length of about from 2 to 12.5mm. A length of from 3 to 7mm is preferred.
  • the use of fibre reinforcement substantially improves the structural integrity of the final product.
  • the resin in the mix may be an epoxy, vinyl ester, polyurethane, polyester, acrylic or phenolic resin, or any hybrid resin system combining two or more of these. An epoxy or vinyl ester is preferred.
  • the micro-spheres have a glass shell and have an average diameter in the range from 10 to 10O ⁇ m, more preferably 20 to 80 ⁇ m.
  • the precursor mixture has a viscosity such that it is pumpable, and is inserted into the hollow member by injecting it under pressure from a conduit through a nozzle into the hollow member.
  • a major part of the mixing of the precursor mixture occurs in a static mixer in the conduit closely upstream of the said nozzle.
  • the set rigid non-foamed mass has a specific gravity between 0.4 and 0.7, more preferably between 0.45 and 0.6, and even more preferably between 0.45 and 0.55.
  • Preferably said precursor mixture is not self levelling on standing prior to hardening.
  • the precursor mixture hardens within or upon the structural member which it is intended to reinforce.
  • the hardening process may be assisted by heating. For an application within the body of an automobile during manufacture of the automobile, such elevated temperatures may be available from the heat treatment of the auto body during its painting operations. In such situations it is preferred for the precursor mixture to be placed into its final position while the auto body is between the electrocoat baking oven and the primer coating station. The hardening process may thus be assisted by heating in the baking oven immediately after the primer application.
  • the body in conventional modern auto finishing, the body is given a total dip electrocoat followed by about 30 minutes in a baking oven where the body is raised to about 1 5°C. Thereafter the body is coated with primer paint and then heated in a primer bake oven for about 20 minutes when it is raised to about 155°C. However if there is a delay in the paint line, such that the body stops in the primer bake oven, it may reach up to about 180°C. Tolerance of such an elevated temperature can be provided by use of an appropriate precursor mixture formulation.
  • a precursor mixture is prepared by mixing two component parts which are formulated from the following ingredients readily available in Australia from the suppliers/manufacturers indicated.
  • the composition is indicated in parts by weight.
  • EPODILTM L adhesion promoter and diluent from Anchor Australia 0 to 40 parts (preferably 20) parts EPODILTM L adhesion promoter and diluent from Anchor Australia,
  • the above ingredients are mixed into the component parts indicated for storage and ease of shipment and handling.
  • the two component parts are independently pumped to, and then brought together, in the weight ratio of 2 parts A to 1 part B, just upstream of a static in-line mixer which is in turn just upstream of the nozzle through which the resultant precursor mixture is injected into the structural member requiring strengthening.
  • a priming piston displacement pump is used for material transfer.
  • a precursor mixture according to the above formulation which is held at a 20°C ambient temperature would gel in around 1 hour and fully cure in around 72 hours.
  • the precursor mixture is injected into chassis rails, roof pillars or other structural members in an auto body under construction, and then introduced into the primer baking oven, the hardening of the precursor mixture is accelerated from that at ambient temperatures, and the filler would be hard by the time the automobile was fully assembled.
  • the hollow micro-spheres also known as micro-balloons, in the above most preferred formulation comprise a 23% loading in the mixture. However from the ranges indicated one can see that variation from about 15% to about 30% are possible.
  • the manufacturer of the micro-spheres states that although the nominal diameter of that grade is 45 ⁇ m, their specification at the same time states that the product sizing is such that 95% has a diameter between 20 ⁇ m and 80 ⁇ m.
  • the hollow glass micro-spheres are added to the mixture to lower the density of the void filler and achieve weight savings. Although micro-spheres of other materials such as plastic or ceramic could be used, high quality glass is considered superior. Micro-spheres made from fly ash, although useable and glassy, are not preferred because, although they have higher strength, their higher density results in a significant undesirable increase in the specific gravity of the final mixture. Upon hardening, the density of a void filler manufactured according to the above description was found to have a specific gravity of 0.51. This was slightly lower than predicted due to incidental and non-intended entrainment of air in the mixture during the mixing process.
  • the present invention encompasses the inclusion of such incidentally entrained air, and such air should be distinguished from air that could be specifically included in order to foam a mixture. Foamed mixtures are not encompassed by the present invention.
  • the precursor mixture of the present invention can be formulated to be not self levelling and thus will not significantly run from where it is placed.
  • the resultant solid void filler could be toughened by adding an elastomer such as 10-40 parts of a carboxylated nitrile rubber to the precursor mixture, using for example CTBN for an epoxy or VTBN for a vinyl ester resin. More preferably though, this would be achieved by adding a toughener such as a difunctional polyoxypropylene with a molecular weight of about 2000, for example JEFFAMINETM D-2000 from Texaco Chemical Co. For this 10-40 parts of the Jeffamine is pre-reacted with the resin at 100°C in an inert atmosphere prior to their mixing with the other ingredients in component part A of the precursor mixture.
  • an elastomer such as 10-40 parts of a carboxylated nitrile rubber to the precursor mixture, using for example CTBN for an epoxy or VTBN for a vinyl ester resin. More preferably though, this would be achieved by adding a toughener such as a difunctional polyoxypropylene with a molecular weight of about 2000, for example
  • epoxy resin in the preferred mixture ensures that it obtains intimate contact and adhesion with the walls even if they are oily from earlier processing or storage.
  • the embodiment described above utilises a primer bake oven to cure the reactant mass
  • the invention in its broader sense envisages the precursor mixture being alternatively inserted into the required positions in the body while it is elsewhere on the assembly line. In its broadest sense, the invention does not require the application of heat to cure the resin. In addition to a speeding of curing, the application of heat for curing can be advantageous where a higher glass transition temperature is sought for the cured material.
  • the precursor mix is prepared by mixing the component parts A & B of the same formulation and in the same ratio as described in detail above.
  • the precursor mix is prepared by mixing the component parts A & B of the same formulation and in the same ratio as described in detail above.
  • Such moulds can be conveniently made of any plastics material suited to blow moulding or vacuum forming of thin walled containers, such as a polyolefin or polyurethane.
  • Inserts may be fastened inside the hollow member to be strengthened by means of screwing, adhesive or by assembling the member to other structural components.
  • hollow member is intended to include channel or trough-shaped members such as C-sections as well as tubular or box-section members.
  • the void filler materials produced by the invention is the very dense packing of the micro-spheres within the matrix of the solid filler.
  • the glass micro-spheres when measured out prior to mixing are of the order of twice the volume of the final mixture into which they become incorporated. They are thus at about twice the packing density in the mixture as they are when freely resting in air.
  • Such very dense packing has been found to be greatly aided by the use of resin components which are of extremely low viscosity and/or by relatively high rates of addition of diluent to further lower viscosity.
  • micro-spheres in the mixture are used in many ways. It is thought that the micro-balloons act as a type of internal lubricant as their spherical shape allows the mixture to flow more freely than what would be otherwise expected, although this comment is not intended to so restrict the nature of the invention.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Composite Materials (AREA)
  • Architecture (AREA)
  • Mechanical Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Structural Engineering (AREA)
  • Civil Engineering (AREA)
  • Materials Engineering (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Body Structure For Vehicles (AREA)

Abstract

L'invention concerne des moyens permettant d'améliorer la résistance de structure métallique creuse, et en particulier d'améliorer la résistance aux impacts d'éléments de structure dans des véhicules à moteur. Les parties à renforcer sont remplies d'une masse non-alvéolaire rigide dont le poids volumique est compris de préférence entre 0,4 et 0,7. Cette masse peut être coulée dans les parties à renforcer ou bien elle peut être moulée extérieurement puis insérée une fois solide. Le mélange précurseur qui durçit peut être pompé et comprend de préférence un époxy ou une résine ester vinylique et un agent de durcissement pour l'époxy ou la résine, des microsphères creuses en verre ou en plastique, et éventuellement des fibres de renforcement, de préférence des fibres de verre.
PCT/AU1995/000482 1994-08-11 1995-08-11 Renforcement structurel WO1996005240A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU31067/95A AU3106795A (en) 1994-08-11 1995-08-11 Structural strengthening

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AUPM7396 1994-08-11
AUPM7396A AUPM739694A0 (en) 1994-08-11 1994-08-11 Structural strengthening

Publications (1)

Publication Number Publication Date
WO1996005240A1 true WO1996005240A1 (fr) 1996-02-22

Family

ID=3781918

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/AU1995/000482 WO1996005240A1 (fr) 1994-08-11 1995-08-11 Renforcement structurel

Country Status (2)

Country Link
AU (1) AUPM739694A0 (fr)
WO (1) WO1996005240A1 (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6086084A (en) * 1995-06-02 2000-07-11 Hunter Douglas Industries B.V. Reinforced elongate metal body
WO2003091325A1 (fr) * 2002-04-23 2003-11-06 Chemco International Limited Matiere legere de nivellement
WO2012140473A1 (fr) * 2011-04-13 2012-10-18 Partes S.R.L. Matériau à mouler pour rembourrages
EP2945982A2 (fr) * 2009-09-16 2015-11-25 Spheritech Ltd Structures poreuses tridimensionnelles

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS50130897A (fr) * 1974-04-04 1975-10-16
DE2936485A1 (de) * 1979-09-10 1981-03-19 Nitta Beruta K.K., Osaka Verfahren zur herstellung eines selbst feuerunterdrueckenden, leichtgewichtigen, zusammengesetzten materials
JPS5993716A (ja) * 1982-11-20 1984-05-30 Nitto Electric Ind Co Ltd 成形品用熱硬化性樹脂組成物
JPH06345953A (ja) * 1993-06-10 1994-12-20 Asahi Chem Ind Co Ltd 軽量強化樹脂組成物

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS50130897A (fr) * 1974-04-04 1975-10-16
DE2936485A1 (de) * 1979-09-10 1981-03-19 Nitta Beruta K.K., Osaka Verfahren zur herstellung eines selbst feuerunterdrueckenden, leichtgewichtigen, zusammengesetzten materials
JPS5993716A (ja) * 1982-11-20 1984-05-30 Nitto Electric Ind Co Ltd 成形品用熱硬化性樹脂組成物
JPH06345953A (ja) * 1993-06-10 1994-12-20 Asahi Chem Ind Co Ltd 軽量強化樹脂組成物

Non-Patent Citations (4)

* Cited by examiner, † Cited by third party
Title
DERWENT ABSTRACT, Accession No. 21657D/13, Class A32; & DE,A,2 936 485 (BERUTA), 19 March 1981. *
DERWENT ABSTRACT, Accession No. 83500Y/47, Class A21; & JP,A,50 130 897 (UBE INDUSTRIES), 16 October 1975. *
JAPIO ONLINE ABSTRACT, Accession No. 84-093716; & JP,A,59 093 716 (NITO ELECTRIC IND), 30 May 1984. *
JAPIO ONLINE ABSTRACT, Accession No. 94-340782; & JP,A,06 345 953 (ASAHI CHEM IND), 20 December 1994. *

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6086084A (en) * 1995-06-02 2000-07-11 Hunter Douglas Industries B.V. Reinforced elongate metal body
US6409183B1 (en) 1995-06-02 2002-06-25 Geert Wemmenhove Reinforced elongate metal body
WO2003091325A1 (fr) * 2002-04-23 2003-11-06 Chemco International Limited Matiere legere de nivellement
GB2404196A (en) * 2002-04-23 2005-01-26 Chemco Internat Ltd Lightweight levelling material
GB2404196B (en) * 2002-04-23 2006-11-01 Chemco Internat Ltd Lightweight levelling material
EP2945982A2 (fr) * 2009-09-16 2015-11-25 Spheritech Ltd Structures poreuses tridimensionnelles
WO2012140473A1 (fr) * 2011-04-13 2012-10-18 Partes S.R.L. Matériau à mouler pour rembourrages
CN103517939A (zh) * 2011-04-13 2014-01-15 特罗尼克有限公司 用于缓冲垫的模制材料

Also Published As

Publication number Publication date
AUPM739694A0 (en) 1994-09-01

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