WO2006066967A1 - Production de moulages laminaires comprenant un materiau expansible supporte sur un support moule - Google Patents

Production de moulages laminaires comprenant un materiau expansible supporte sur un support moule Download PDF

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Publication number
WO2006066967A1
WO2006066967A1 PCT/EP2005/014057 EP2005014057W WO2006066967A1 WO 2006066967 A1 WO2006066967 A1 WO 2006066967A1 EP 2005014057 W EP2005014057 W EP 2005014057W WO 2006066967 A1 WO2006066967 A1 WO 2006066967A1
Authority
WO
WIPO (PCT)
Prior art keywords
carrier
foamable material
temperature
operation according
moulded
Prior art date
Application number
PCT/EP2005/014057
Other languages
English (en)
Inventor
Jean-Yves Valentin
Luc Mezzetta
Jean-Jacques Undereiner
Original Assignee
L & L Products Inc
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
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=34090359&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=WO2006066967(A1) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by L & L Products Inc filed Critical L & L Products Inc
Priority to EP05821568A priority Critical patent/EP1827788A1/fr
Publication of WO2006066967A1 publication Critical patent/WO2006066967A1/fr

Links

Classifications

    • 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
    • B29C44/04—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 consisting of at least two parts of chemically or physically different materials, e.g. having different densities
    • 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
    • B29C44/18—Filling preformed cavities
    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0053—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping
    • B29C45/006—Joining parts moulded in separate cavities
    • 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
    • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous

Definitions

  • the present invention relates to the production of laminar mouldings that comprise foamable material supported on a moulded carrier.
  • Laminar mouldings that comprise foamable material supported on a moulded carrier find uses a reinforcing components in the automobile and other industries. They are particularly useful in systems where the foamable material is designed to expand at temperatures employed after metal coating operations so that the laminar moulding may be placed inside the metal frame of a vehicle whilst leaving a clearance between the moulding and the metal frame to allow the metal coating operation. Following the metal coating operation such as in the heated drying and baking of the coating the foamable material is foamed to bridge the clearance and bond the carrier to the interior wall of the metal frame of the vehicle.
  • the carrier may be from a thermoplastic material and produced by extrusion, blow moulding or injection moulding.
  • the carriers are sometimes complex in shape or configuration and then injection moulding is the preferred method of production.
  • the carrier may be a metal in which case it may be produced by cutting or stamping.
  • the foamable layer can be applied to the carrier in a variety of ways. For example it may be overmoulded onto the injection moulded carrier although this suffers from the disadvantage that two separate moulds and moulding operations are required. Alternatively the foamable material may be extruded, cut into ribbons and adhesively bonded to the carrier, this is however a laborious and time consuming process.
  • injection moulding is a preferred technique for the production of the carrier.
  • Overmoulding has been the preferred technique to provide the foamable material on the surface of the carrier.
  • the foamable material in order to successfully overmould the foamable material the foamable material must be such that it will flow readily under the over moulding conditions, and will not foam, will not degrade and will adhere to the injection moulded carrier.
  • laminar mouldings are produced in a moulding operation in which a carrier material is formed in a first injection process performed at a first temperature and a foamable material is formed in a second parallel injection process performed at a lower temperature and the foamable material is transferred to the surface of the carrier material at a temperature such that the foamable material becomes heat bonded to the carrier material but does not foam.
  • the moulded foamable material may be transferred to the surface of the moulded carrier as it is cooling down from its moulding temperature.
  • the moulded carried and the moulded foamable material may both be removed from their respective moulds and transferred to a temperature controlled environment when the temperature is maintained at a level where the foamable material softens and is adhesive and does not foam.
  • the moulded foamable material may then be transferred onto the surface of the carrier.
  • reinforcing members tend to be larger and to have a more complex structure than previous structural reinforcing members. It has been found that such structures can be conveniently formed by injection moulding of thermoplastics and accordingly it is preferred that the carrier be produced by injection moulding, preferably of polypropylene or nylon and particular nylon that is fibre filled especially glass filled nylon. Polyamides, particularly glass filled polyamides are suitable materials due to their high strength to weight ratio. It is preferred that the moulding is provided with means enabling fluid drainage. For example, holes may be provided in the moulding to allow the drainage of water, which may condense in the structure over time.
  • foamable materials examples include foamable epoxy-base resins and examples of such materials are the products L5206, L5207, L5208 and L5209, which are commercially available from L & L Products of Romeo Michigan USA, and the Core Products 5204, 5206, 5205 and 5208 available from Core Products, France, France.
  • the product should be chosen so that it softens and becomes adhesive at temperatures below that at which it foams and according to the rate of expansion and foam densities required. It is further preferred that it expand at the temperatures experienced in the oven used to dry and cure the anticorrosion coating deposited in the e-coat process, typically 13O 0 C to 15O 0 C.
  • the expandable adhesive material is preferably dry and not tacky to the touch at ambient temperature, since this facilitates shipping and handling and prevents contamination.
  • the foamable material will foam at a lower temperature.
  • Hitherto foamable materials have been designed to foam at temperatures between 165 0 C and 185°C, the temperatures employed for the drying and baking of the anticorrosion coating in the e-coat process.
  • Foaming temperatures of between 115°C and 140 0 C are however preferred in the present invention. It is of course necessary that little if any foaming of the foamable material should occur during the moulding and bonding of the foamable material according to the process of this invention.
  • a foamable material that can be moulded and bonded at temperatures below 120 0 C preferably below 11O 0 C and which can be foamed at temperatures between 115 0 C and 140°C preferably between 120 0 C and 135 0 C.
  • Preferred foamable materials comprise an epoxy resin that softens and flows below 120°C preferably below 110 0 C and containing a blowing agent and a curing agent that are activated at temperatures in the range 115 0 C to 140 0 C 1 preferably in the range 120 0 C to 135°C when the invention is sued to produce reinforcing members for automobiles.
  • the foamable material may be chosen so that it will foam under the conditions that are used to dry the e-coat which is typically cured in an oven after application by dipping.
  • the members should be provided with means whereby they can be placed and retained in the appropriate location in the vehicle.
  • the reinforcing members are placed in the vehicle by robots and the members are therefore preferably provided with locator means to enable the robot to locate the member and lift it and place it in the vehicle.
  • the locator means may comprise locations such as holes in the member which can be located by sensors on the robot.
  • the member can be provided with extensions which enable the robot to pick up the member and transfer it to the appropriate location in the vehicle metal structure.
  • the manner by which the member is retained within the metal structure depends upon the position of the part within the structure and if it is provided to a horizontal or inclined element of the vehicle metal structure. If the member is provided to lie horizontally within the metal structure it may be provided with tabs which enable it to rest on the metal structure. In other environments clips or other forms of attachment may be required.
  • the process is used to produce reinforcing members that are to be used for strengthening automobiles it is important that the e-coat anticorrosion fluid which is applied prior to foaming can flow through the tubular metal structures when the vehicle metal structure containing one or more reinforcing members passes through the bath of the fluid. Accordingly it may be necessary to provide channels in the reinforcing member to enable flow of the e-coat fluid. Furthermore it may be necessary to ensure provision of an adequate gap between the foamable material and the metal for flow of the e-coat fluid. Such a gap may be provided by an appropriate means of attachment or spacers such as is illustrated in Japanese Patent Application 7-117728.
  • the structural reinforcing member may be provided with small lugs, which enable it to stand away from the interior walls of the hollow structure. In this way fastening devices may not be required and the area of contact between the structural reinforcing member and the interior walls of the frame of the vehicle is minimised.
  • the clearance between the extremity of the reinforcing member and the interior walls of the hollow section should preferably be wide enough to enable the liquid used in the electrocoat bath to flow between the reinforcing member and the interior walls of the sections of the vehicle in sufficient quantity to enable an effective anti-corrosion coating to be deposited.
  • the clearance must not be too wide since this can result in a lack of rigidity in the structure when the expandable adhesive is foamed to bond the structural reinforcing member to the walls of the hollow section other than the external panel. It is preferred that the clearance be no more than 1 centimetre and is more preferably 3 to 10 millimetres.
  • a dual component moulding may be manufactured by a process in which the carrier is produced by injection moulding in a first cavity.
  • the carrier is produced from polyamide and particularly glass filled polyamide it will be injected at a temperature of between 15O 0 C and 190 0 C.
  • the foamable material may be simultaneously injected into a second cavity in order to produce a pattern of the foam it is desired to apply to the carrier.
  • the foamable material is an epoxy foam it is typically injected at a temperature of between 100 0 C and 120 0 C being a temperature below that at which the material will foam.
  • the carrier Once the carrier has been formed by injection at the desired temperature it is cooled usually by cooling the mould. As the carrier cools its temperature will pass through the temperature range at which the foamable material will soften but not foam because it is at a temperature below its foaming temperature. The foamable material may be brought into contact with the moulded carrier while it is at this temperature so that it will soften and adhere to the carrier to produce a structural reinforcing member.
  • stage 1 injection moulding
  • a nylon carrier (1 ) and the desired foam structure (2) are separately moulded.
  • they are then placed in a controlled temperature environment (regulated pre-heating) where their temperatures are controlled by heaters (3) and (4).
  • they are at the desired temperature they are brought together (heat bonding) to form the desired part (5).

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Body Structure For Vehicles (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)

Abstract

L'invention concerne des moulages laminaires comprenant un matériau expansible (2) supporté sur un support moulé (1) et obtenus, simultanément, par moulage du support à une première température et du matériau expansible à une température inférieure et par mise en contact du matériau expansible moulé avec le support moulé à une température à laquelle il adhère sur le support, de manière à produire le moulage laminaire.
PCT/EP2005/014057 2004-12-21 2005-12-21 Production de moulages laminaires comprenant un materiau expansible supporte sur un support moule WO2006066967A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP05821568A EP1827788A1 (fr) 2004-12-21 2005-12-21 Production de moulages laminaires comprenant un materiau expansible supporte sur un support moule

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0427837.0 2004-12-21
GB0427837A GB2421468A (en) 2004-12-21 2004-12-21 Bonding moulded foamable material to a moulded carrier

Publications (1)

Publication Number Publication Date
WO2006066967A1 true WO2006066967A1 (fr) 2006-06-29

Family

ID=34090359

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2005/014057 WO2006066967A1 (fr) 2004-12-21 2005-12-21 Production de moulages laminaires comprenant un materiau expansible supporte sur un support moule

Country Status (4)

Country Link
EP (1) EP1827788A1 (fr)
GB (1) GB2421468A (fr)
RU (1) RU2007127917A (fr)
WO (1) WO2006066967A1 (fr)

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH1071628A (ja) * 1996-08-30 1998-03-17 Neox Lab:Kk 中空構造物における中空室遮断具とその製造方法
EP1149679A2 (fr) * 2000-04-26 2001-10-31 Neo-Ex Lab. Inc. Dispositifs et structures pour le renforcement d'éléments creux de construction
US20020053179A1 (en) * 1996-05-10 2002-05-09 Wycech Joseph S. Internal reinforcement for hollow structural elements.
EP1484162A1 (fr) * 2003-06-04 2004-12-08 Weener Plastik GmbH & Co. KG Procédé de fabrication d'un corps en matière plastique et récipient

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1127921A (en) * 1963-12-20 1968-09-18 Eric Alfred Luddington Improvements in or relating to boxes or packets
US4005975A (en) * 1972-12-08 1977-02-01 Tetra Pak Developpement Sa Apparatus for connecting together parts of foam plastics
JPS59232829A (ja) * 1983-06-15 1984-12-27 Sumitomo Bakelite Co Ltd ポリ塩化ビニル発泡体の成形方法
IT1267366B1 (it) * 1994-12-30 1997-01-28 Edison Termoelettrica Spa Procedimento per la realizzazione di un elettrodo per batterie al piombo-acido dipolari con cornice periferica sigillante, e prodotto
DE19858903B4 (de) * 1998-12-19 2015-07-23 GM Global Technology Operations LLC (n. d. Ges. d. Staates Delaware) Verstärkungselement für einen Hohlkörper, insbesondere für einen Fahrzeugkarosserieholm, Verfahren zum Einbringen eines solchen Verstärkungselementes in einen Hohlkörper und Fahrzeugkarosserie mit einem derart verstärkten Karosserieholm

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20020053179A1 (en) * 1996-05-10 2002-05-09 Wycech Joseph S. Internal reinforcement for hollow structural elements.
JPH1071628A (ja) * 1996-08-30 1998-03-17 Neox Lab:Kk 中空構造物における中空室遮断具とその製造方法
EP1149679A2 (fr) * 2000-04-26 2001-10-31 Neo-Ex Lab. Inc. Dispositifs et structures pour le renforcement d'éléments creux de construction
EP1484162A1 (fr) * 2003-06-04 2004-12-08 Weener Plastik GmbH & Co. KG Procédé de fabrication d'un corps en matière plastique et récipient

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
PATENT ABSTRACTS OF JAPAN vol. 1998, no. 08 30 June 1998 (1998-06-30) *

Also Published As

Publication number Publication date
RU2007127917A (ru) 2009-01-27
GB0427837D0 (en) 2005-01-19
EP1827788A1 (fr) 2007-09-05
GB2421468A (en) 2006-06-28

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