Static structures (e.g. – buildings) – Machine or implement
Reexamination Certificate
2000-01-31
2001-07-03
Friedman, Carl D. (Department: 3635)
Static structures (e.g., buildings)
Machine or implement
C052S749100, C052S749100, C052S749100, C296S187060
Reexamination Certificate
active
06253524
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention concerns the use of thermally expansible foaming materials, particularly thermally expansible foaming structural reinforcing materials, which are coupled to a carrier having a directional foaming shelf mounted thereon to direct the structural reinforcing material during foaming to a particular area on a surrounding structural member giving additional localized stiffness to frames, rails, structure surrounding cavities, panels and other structural members. Such a reinforcing member may be useful in architectural, automotive, aviation, marine, or any other applications where increased support or stiffness would reduce vibration, noise and/or fatigue propagation, or would provide reinforcement to enhance structural strength or provide energy management during crash, crush or impact encounters.
2. Description of the Prior Art
It has long been recognized that foamable materials may be used to bond together separate components. Structural foams, urethanes, and other thermally expansible foaming materials have been used to enhance acoustic performance and provide structural rigidity. Examples of thermally expansible structural reinforcing materials used on carriers in the automotive field are illustrated in U.S. Pat. No. 5,194,199 to Thum, U.S. Pat. No. 5,344,208 to Bien et al., and U.S. Pat. Nos. 5,575,526 and 5,755,486 to Wycech. Another example of the use of thermally expansible materials on a carrier and used primarily as a baffle composition is shown in U.S. Pat. No. 5,506,025 to Otto et al. An example of the use of a foamable material on a beam-shaped structure in a piling is shown in U.S. Pat. No. 4,019,301 to Fox et al.
While such showings disclose various uses of expansible materials in reinforcing, baffling and sealant applications, there has developed a need for a simplified reinforcing member which will provide stiffening and reinforcement to a surrounding structural member. The use of expansible reinforcing materials which are initially dry and non-tacky are preferred in the manufacturing context. Such materials having shipping and handling advantages; notably this type of reinforcing material does not readily adhere to shipping containers, to workers during manufacture and installation, or to other critical surfaces which may come into contact with the material. By being non-tacky, these materials will not readily retain dirt, dust or other contaminants. Additionally, these materials will not readily adversely adhere to a carrier positioned within the structural member which helps to position the reinforcing member prior to expansion of the reinforcing material.
SUMMARY OF THE INVENTION
The reinforcing member of the present invention provides significant advantages over prior carrier and expansible material combinations in manufacturing, handling and use by providing directional foaming to orient and localize the expansion and bonding of the thermally expansible foaming reinforcing material to the structural member. The reinforcing member provides support to an adjacent structural member through the foamed reinforcing material positioned on a directional foaming shelf supported by the carrier, with the carrier being configured to include a mechanical fastening element to couple the thermally expansible foaming structural reinforcing material and the directional foaming shelf to the carrier. The directional foaming shelf is apertured, whereby the reinforcing material expands therethrough during foaming and thereby bonds to the carrier, the directional foaming shelf and the surrounding structural member to provide a reinforced structural member. The carrier may be provided of various configurations and is preferably designed to provide both a mounting surface which couples to the structural member and properly locates the reinforcing material and directional foaming shelf thereon and may provide additional structural reinforcement. The use of mechanical fasteners enables the initially non-tacky structural reinforcing material and directional shelf to be positioned in various locations and orientations whereby upon activation, the reinforcing material may foam, thereby expanding to bond the carrier and the directional shelf to the surrounding structure.
Broadly speaking, the present invention includes a carrier which has at least one and preferably two or more surfaces for receiving a directional foaming shelf thereon, and for coupling to the structural member. The directional foaming shelf includes a platform and two or more walls angularly oriented with respect thereto. The platform includes at least one aperture to permit the thermally expansible foaming reinforcing material to flow therethrough, whereby a bond is provided between the reinforcing material and the carrier to which the shelf is attached. The walls serve to constrain and direct the reinforcing material during foaming, thereby causing the reinforcing material to engage and bond to a particular area on the structural member and further to protect some areas against engagement with the reinforcing material after foaming and expansion. This may reduce the amount of reinforcing material required in a particular application. By providing the directional foaming shelf as a separate element from the carrier, one carrier can be used for a variety of different applications by merely substituting different directional foaming shelves. The fastener may be provided separately or as a part of the carrier, and preferably provides some yield or give to permit the material to shift upon impact and provide manufacturing tolerance. In one embodiment, the fastener may be provided as a synthetic resin pin passing through the material, the directional foaming shelf and through an opening in the carrier. In another embodiment, the fastener may be provided as a tab which may be bent to grasp the material and hold it and the directional foaming shelf to the carrier. The reinforcing member is typically received in a structural member such as a rail or channel which provides a cavity for receiving the structural member therein with the reinforcing material in engagement with or proximate to the structural member prior to activation.
The reinforcing material is thermally expansible, either by internally created thermal energy or by the external application of heat to activate the material. As used herein, the term “thermally expansible” means to foam and thereby expand by both internally created thermal energy and the external application of heat to expand and foam the reinforcing material. The thermally expansible reinforcing material is preferably a synthetic resin-based material which foams when subjected to temperatures achieved during baking in a manufacturing process (e.g., such as during the paint and powder coat bake stage of automobile manufacturing processes). Thus, the expansion temperature of the material should be at least about 300° F.
The foregoing advantages to the present invention will be readily appreciated by those skilled in the art with reference to the drawings and description which follow, which are intended to be exemplary rather than limiting.
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patent: 576
Chang Chin-Jui
Hopton Gregory W.
Friedman Carl D.
Hovey Williams Timmons & Collins
Nguyen Chi
SIKA Corporation
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