WO2014176477A1

WO2014176477A1 - Activatable material and carrier attachment

Info

Publication number: WO2014176477A1
Application number: PCT/US2014/035397
Authority: WO
Inventors: Kevin RENNO; Craig LANGEVIN; Todd Deachin
Original assignee: Zephyros Inc
Current assignee: Zephyros Inc
Priority date: 2013-04-26
Filing date: 2014-04-25
Publication date: 2014-10-30
Anticipated expiration: 2015-10-26
Also published as: CN105358301A; BR112015027052A2; US20140322464A1; BR112015027052B1; KR20160005693A; KR102246757B1; CN105358301B

Abstract

A method for making an activatable insert, comprising the steps of locating a carrier (10) having at least one hollow columnar projection (12a) in an overmolding tool the at least one hollow columnar projection having an intermediate portion (14) and a free end portion (16), wherein the intermediate portion (14) and the free end portion (16) each have generally the same perimeter dimension; deforming the at least one hollow columnar projection (12a) while it is within the overmolding tool to form a permanently deformed projection such that the free end portion (16) of the permanently deformed projection has a perimeter dimension that exceeds the perimeter dimension of the intermediate portion (14); and overmolding an activatable material (20) onto the carrier so that the activatable material substantially surrounds the deformed projection, and the deformed projection helps to retain the activatable material on the carrier.

Description

ACTIVATASLE MATERIAL AND CARRIER ATTACHMENT

Technical Field

[0001] The present invention pertains generally to activatabie inserts for filling an automotive vehicle cavity, and more particularly to activatabie inserts that employ an improved in situ formed mechanical interlock connection between a carrier and a material that is activatabie for expansion.

Background

[0002J in the automotive vehicle field there are a number of applications in which an activatabie material is attached to a carrier. The activatabie material may be activated by heat, moisture, radiation or some other stimulus to cause it to flow, seal, expand or otherwise change state while in a vehicle cavity. A carrier is commonly employed for supporting the activatabie material, and for securing the part within a vehicle cavity. For example, one or more dips may project from the carrier for clipping the part into an opening in vehicle sheet metal.

[0003] Particularly if an application seeks to avoid the additional processing step of heat bonding of activatabie material to the carrier, there are a number of alternative ways for attaching such activatabie materials to a carrier. Examples include the use of solid molded posts, mushroom caps of activatabie material that penetrate though an aperture, or even mechanical fasteners (e.g., a staple). Notwithstanding these approaches, there remains a need for yet additional alternatives. Attractive alternatives include those alternatives by which secondary operations for attaching the activatabie material can be avoided after overmolding.

Summary of the Invention

[0004] The teachings herein contemplate a method for making an activatabie insert, comprising the steps of locating a carrier having at least one hollow columnar projection in an overmolding tool, the at least one hollow columnar projection having an intermediate portion and a free end portion, wherein the intermediate portion and the free end portion each have generally the same perimeter dimension; deforming the at least one hollow columnar projection while it is within the overmolding tool to form a permanently deformed projection such that the free end portion of the permanently deformed projection has a perimeter dimension that exceeds the perimeter dimension of the intermediate portion; and overmolding an activatabie material onto the carrier so that the activatabie materia! substantially surrounds the deformed projection, and the deformed projection (e.g., due to a flared shape) helps to retain the activatable material on the carrier,

[0005] The teachings herein also contemplate an activatable insert for insertion in a cavity of an automotive vehicle, comprising: a poiymeric carrier having at least one deformed hoiiow columnar projection that has a free end and an end that is proximal a base wall of the carrier, the free end having an outer perimeter dimension that is enlarged relative to an outer perimeter dimension at an intermediate location along the projection; an activatabie materia! overmolded onto the polymeric carrier and being held on the poiymeric carrier by the at !east one deformed hollow coiumnar projection.

[00083 T e teachings herein provide for a simplified method of securely attaching a material layer (e.g., an activatable materia!) to a carrier, whereby the attachment process takes place simultaneously during molding of the material layer onto the carrier such thai no additional processing steps are necessary.

Description of the Drawings

[00073 Fig. 1 illustrates an example of a section of a carrier according to the present teachings before overrnoiding.

[00083 Fig, 2 illustrates an example of the section of Fig. 1 after overmoiding.

[0009] Fig. 3a is a view of one side of an article in accordance with the present teachings.

[0010] Fig. 3b is a view of an opposite side of the article of Fig, 3a.

[0011] Fig. 4 is an enlarged view of a portion of Fig. 3a.

[00123 Fig. 5 is a perspective view of an illustrative part made with the attachment of the present teachings, including an activatabie materia! on a carrier, and attachment devices on a side edge.

[00133 Fig. 6 is a side profile view of the part shown at Fig. 5.

Detailed Descriptiorj

[0014J This application claims the benefit of the filing date of U.S. Provisional Application Serial Mo. 61/816,220 filed Apri! 25, 2013, the contents of such application being hereby incorporated by referenc for all purposes.

[00153 The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the teachings, its principles, and its practical application. Those skilled in the art may adapt and app!y the teachings in its numerous forms, as may be best suited to the requirements of a particular use. Accordingly, the specific embodiments of the present teachings as set forth are not intended as being exhaustive or limiting of the teachings. The scope of the teachings should, therefore, be determined not with reference to the above description, but shouid instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. Other combinations are also possible as will be gieaned from the following claims, which are also hereby incorporated by reference into this written description,

[0016] The teachings herein make advantageous use of a simple, but elegant solution to difficulties faced when having to join activatable materials (e.g., any secondary materia! layer) with a carrier. Activatable materials herein are typically polymeric materials that upon being subjected to a stimulus (e.g., heat, moisture, radiation, or any combination thereof) will flow, seal, expand and/or otherwise change state. Typically, such stimulus arises upon being subjected to heat from a paint bake operation in automotive paint shop, tt is common for such materials, upon exposure to heat, to expand and fill a cavity. It is common to employ carriers that support the activatable material. In some instances, it is possible that the activatable material will heat bond to the carrier. But, this may be impraeticai in some instances.. Thus, in accordance with the teachings herein, there is disclosed a unique, simple yet elegant solution for securing activatable material to a carrier.

[00173 The carrier may be formed by an injection molding process. The carrier may be formed by an extrusion process. The projections referred to herein for attaching the activatable material to the carrier may be integrally formed with the carrier during formation of the carrier. Alternatively, the projections may be located onto the carrier via a secondary connecting process (such that the projections are not integrally formed with the carrier). The projections may be formed having any shape or profile. In one embodiment, the projections are columnar in shape. The projections may be formed in any shape that allows for easy deformation of the projection during an overmoiding process. Such deformation may form a projection having a free end having a larger perimeter than any other adjacent portion of the projection such that the expanded free end acts to maintain any material overmolded onto the carrier below the free end (or at least not extending beyond a terminating edge of the projection. As a result, the deformed free end (or at least a portson thereof) may be visible even after overmoiding a material layer onto the carrier. However, upon activation of the material layer, the visible end of the projection may no longer be visible.

[0018] Deformation of the projection during the overmoiding process simplifies part production and processing in that additional processing steps or fastening mechanisms are no longer required for attaching a secondary (e.g., activatable) materia! to the carrier. This resu!ts in a substantial reduction in cycle time for the part and may also result in reduced materia! usage.

[0019] The activatabie material may be a polymeric materia! that is activated to flow, seal, expand or any combination thereof, it may be a materia! that forms a foam (e.g., an acoustic foam or a structural foam). It may expand from its origina! volume to at least 150%, 300%, 500%, or even 1000% or larger of its original volume.

[00203 The activatable material may be activated when subjected fo heat during paint shop baking operations, in applications where the activatable materia! is a heat activated, thermally expanding materia!, an important consideration involved with the selection and formulation of the material comprising the activatable material is the temperature at which a material reaction or expansion, and possibly curing, will take place. For instance, in most applications, it is undesirable for the materia! to be reactive at room temperature or otherwise at the ambient temperature in a production line environment. More typically, the activatabie materia! becomes reactive at higher processing temperatures, such as those encountered in an automobile assembly plant, when the material is processed along with the automobile components at elevated temperatures or at higher applied energy levels, e.g., during paint or e-coat curing or baking steps. While temperatures encountered in an automobile assembly operation may be in the range of about 148.89¹¹ C. to 204.44° C. (about 300⁴¹ F. to 400" P.), body and paint shop applications are commonly about 93.33° C. (about 200^Λ F.) o slightly higher. One or more sides of the activatab!e material may be tacky. One or more sides of the activatable materia! may be generally tack free to the touch at room temperature. Following activation of the activatabie material, the material will typically cure. Thus, it may be possible that the activatable materia! may be heated, it may then expand, and may thereafter cure to form a resulting foamed material.

[0021j The carrier may be any suitable material. Desirably if will have a melting point or glass transition temperature that is higher than that of the activatable maieriaL in this way, the carrier will generally retain its as-molded shape during overmo!ding (with the exception of the free end of the column projection). An example of a material is a polyamide, such as !Niy!on 86. The carrier may include other features, such as a c!ip for mounting the carrier within a cavity of an automotive vehicle.

[00223 To show specific examples of the methods and inserts discussed herein, with reference to Fig. 1 , there is seen a section of a carrier 10 (e.g., a molded polymeric carrier., such as a molded polyamide carrier) that includes at least one projection 12a that projects from a base 12b. The projection has an intermediate portion 14 and a free end 18. The projection may be a hollow column for at ieast a portion of its height. Prior to any overmolding, the outer periphera! dimension of the intermediate portion 14 is genera!iy the same as that of the free end 16. As seen in Fig. 2, during overmolding, it is envisioned that a tool portion 18a will apply sufficient force io the free end to permanently deform the free end so that it has an outer peripheral dimension that is larger than that of the intermediate portion, in this manner, a lip 16' is effectively formed at the free end that can be empioyed for mechanically retaining the activatable materia! 20 on the carrier 10. For instance, when the carrier 10 placed between tool portions 8a and 18b, the tool portion 18a causes the end 16' to permanently flare out or mushroom. The structure that causes attachment of the activatable materia! 20 to the carrier 10 is thus formed in situ when the tool portions 18a and 18b ar brought together during an overmolding step (e.g., when the molding press is closed). The resulting height of the projection 12a is approximately the thickness of the activatable materia! 20. The resulting periphera! dimension of the flared end 16' may be at least 5%, 10%, 20%, 50% or larger than its original state. The outermost portion of the flared end 16' may be generally co-planar with or above an upper surface 22 of the activatabSe material.

[0023] Figs. 3a and 3b illustrate an article made in accordance with the present teachings. As seen an elongated carrier 10 supports an activatable materia! 20, In the embodiment shown, activatab!e materia! encircles c!ips 22 formed integra!!y with the carrier. Further, multiple projections 12a are shown. Both the dips 22 and projections 12a are substantially surrounded by the activatabie material 20. This is shown particularly in Fig. 4, which also depicts multiple distinct attachment features of the present teachings. Projections 12a attach activatabie material 20 to the carrier 10. A clip 22 may be surrounded by activatable material 20. Such activatable material may remain in place mechanically, e.g. in the absence of an adhesive bond between the carrier and the activatable material.

[0024j Pigs- 5 and 6 depict additional parts including the columnar projections 12a for attaching the activatable material 20 to the carrier 10. The projections are shown having a free- end 18^: that f!ares out or "mushrooms" to cause attachment of the expandable material to the carrier. The parts inc!ude clips 22 that project outwardly generally in a plane that lies below a planar portion of the carrier.

[00253 The methods herein may be free of any secondary operation of tooling, subsequent to overmolding, for causing the at least one holiow columnar projection to help retain the activatable material on the carrier. The overmolding may be performed as part of a rotary injection molding operation. Further, the activatable material is retained on the carrier in the substantial absence of any heat bonding of the activatable materia! to the carrier. The activatabie materia! may be retained on the carrier in the substantial absence of any secondary fastener for bonding the activatabie material to the carrier. The method may include activating the activatabie material. The free end of the projections may be visible after ovenmolding the activatabie material onto the carrier but prior to any activation of th activatabie materia!. The method may be used to form an insert that may include at least one connecting element for mechanically interlocking an aperture in sheet metal of an automotive vehicle. The insert may be free of any secondary fastener for connecting the activatabie materia! to the carrier. The insert may include projections having a free end which may or may not be visible after overmolding the activatabie materia! onto the carrier. The free end of a projection may not be visible after activation of the activatabie materia!.

[0026] The teachings herein afford a way to retain activatabie materia! on a carrier, and is especially suitable for many instances when attachment is not otherwise attainable. The techniques herein may be used in transfer moiding processes. The techniques herein may be used in insert molding processes.

[00273 As used herein, unless otherwise stated, the teachings envision that any member of a genus (list) may be excluded from the genus; and/or an member of a Ivlarkush grouping may be excluded from the grouping,

[0028] Unless otherwise stated, any numerical values recited herein include all values from the lower value to the upper value in increments of one unit provided that there is a separation of at least 2 units between any lower value and any higher value. As an example, if it is stated that the amount of a component, a property, or a value of a process variable such as. for example, temperature, pressure, time and the like is, for example, from 1 to 90, preferably from 20 to 80, more preferably from 30 to 70, it is intended that intermediate range values such as (for example, 15 to 85, 22 to 68, 43 to 51, 30 to 32 etc.) are within the teachings of this specification. Likewise, individual intermediate values are also within the present teachings. For values which are less than one, one unit is considered to be 0.0001 , 0.001, 0.01 , or 0.1 as appropriate. These are only examples of what is specifically intended and all possible combinations of numerical values between the lowest value and the highest value enumerated are to be considered to be expressly stated in this application in a similar manner. As can be seen, the teaching of amounts expressed as "parts by weight" herein also contemplates the same ranges expressed in terms of percent by weight. Thus, an expression in the of a range in terms of at "'χ' parts by weight of the resulting polymeric b!end composition" also contemplates a teaching of ranges of same recited amount of "x" in percent by weight of the resulting polymeric blend composition " [00293 Unless otherwise stated, ail ranges include both endpoints and ail numbers between the endpoints. The use of "about" or "approximately" in connection with a range applies to both ends of the range. Thus, "about 20 to 30" is intended to cover "about 20 to about 30", inclusive of at least the specified endpoints.

[0030] The disclosures of ail articles and references, including patent applications and publications, are incorporated by reference for ail purposes. The term "consisting essentially of to describe a combination shall include the elements, ingredients, components or steps identified, and such other elements ingredients, components or steps that do not materially affect the basic and novel characteristics of the combination. The use of the terms "comprising" or "including" to describe combinations of elements, ingredients, components or steps herein also contemplates embodiments that consist of, or consist essentially of the elements, ingredients, components or steps.

[00313 P!urai elements, ingredients, components or steps can be provided by a single integrated element, ingredient, component or step. Alternatively, a single integrated element, ingredient, component or step might be divided into separate plural elements, ingredients, components or steps. The disclosure of "a" or "one" to describe an element, ingredient, component or step is not intended to foreclose additional elements, ingredients, components or steps,

[0032] it is understood that the above description is intended to b illustrative and not restrictive. Many embodiments as we!i as many applications besides the examples provided will be apparent to those of skill in the art upon reading the above description. The scope of the invention should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the fui! scope of equivalents to which such claims are entitled. The disclosures of ail articles and references, including patent applications and publications, are incorporated by reference for ali purposes. The omission in the following claims of an aspect of subject matter that is disclosed herein is not a disclaimer of such subject matter, nor should if be regarded that the inventors did not consider such subject matter to be part of the disclosed inventive subject matter..

Claims

What is claimed is:

1 ) A method for making an aciivatabie insert, comprising the steps of;

a. locating a carrier having at least one hollow columnar projection in an overmoiding tool the at least one hollow columnar projection having an intermediate portion and a free end portion, wherein the intermediate portion and the free end portion each have generally the same perimeter dimension;

b. deforming the at least one hollow columnar projection while it is within the

overmoiding tool to form a permanently deformed projection such that the free end portion of the permanently deformed projection has a perimeter dimension that exceeds the perimeter dimension of the intermediate portion; c. overmoiding an aciivatabie material onto the carrier so that the aciivatabie

material substantially surrounds the deformed projection, and the deformed projection heips to retain the aciivatabie materia! on the carrier.

2) The method of claim 1 , wherein the step of iocating inciudes injection molding the carrier having the at least one hoiiow columnar projection.

3) The method of claim 1 or 2, wherein the method is free of any secondary operation of tooling, subsequent to overmoiding, for causing the at least one hoiiow columnar projection to help retain the aciivatabie materia! on the carrier.

4} The method of any of ciaims 1 through 3, wherein the overmoiding is performed as part of a rotary injection molding operation.

5} The method of any of ciaims 1 through 4, wherein the aciivatabie materia! is retained on the carrier in the substantias absence of any heat bonding of the aciivatabie materia! to the carrier,

6) The method of any of ciaims 1 through 5, wherein the aciivatabie materia! is retained on the carrier in the substantia! absence of any secondary fastener for bonding the aciivatabie material to the carrier.

7) The method of any of ciaims 1 through 8, inciuding integrally forming the columnar

projection with the carrier. 8) T!ie method of any of claims 1 through 7, wherein the step of locating includes extruding the carrier having the at least one columnar projection.

9) The method of any of claims 1 through 8, including activating the activatabie material.

10) The method of any of claims 1 through 9, wherein the free end is visible after

overmoiding the activatabie materia! onto the carrier but prior to any activation of the activatabie materia!,

11 ) An activatabie insert for insertion in a cavity of an automotive vehicle., comprising;

a. a polymeric carrier having at least one deformed hofiow columnar projection that has a free end and an end that is proximal a base wall of the carrier, the free end having an outer perimeter dimension that is enlarged relative to an outer perimeter dimension at an intermediate location along the projection; b, an activatabie materia! overmolded onto the polymeric carrier and being held on the polymeric carrier by the at !east one deformed ho!iow columnar projection.

12) The activatabie insert of claim 1 1 , wherein the insert includes at least one connecting element for mechanically interlocking an aperture in sheet metal of an automotive vehicle.

13) The activatabie insert of claim 11 or claim 12, wherein the insert is free of any secondary fastener for connecting the activatabie material to the carrier.,

14) The activatabie insert of any of claims 11 through 13, wherein the free end is visible after overmoiding the activatabie material onto the carrier.

15) The activatabie insert of any of claims 1 1 through 13, wherein the free end is not visible after overmoiding the activatabie materia! onto the carrier.

16) The activatabie insert of any of claims 11 through 15, wherein the free end is not visible after activation of the activatabie material. 17) The activatabie insert of any of claims 1 1 through 18, wherein the columnar projection is integrally formed with the carrier.

18) The activatabie insert of any of claims 1 through 17, wherein the activatabie material is overmoided onto the carrier as part of a rotary injection molding operation.

19) The activatabie insert of any of claims 11 through 18, wherein the carrier is injection molded or extruded.

20) The activatabie insert of any of claims 1 through 19, wherein the activatabie material is retained on the carrier in the substantial absence of any heat bonding of the activatabie materia! to the carrier.