Joints and connections – Branched – Three or more radiating members
Reexamination Certificate
2000-01-04
2001-12-25
Browne, Lynne H. (Department: 3629)
Joints and connections
Branched
Three or more radiating members
C403S269000, C403S265000, C296S030000, C156S293000
Reexamination Certificate
active
06332731
ABSTRACT:
TECHNICAL FIELD
The present invention relates generally to reinforcement of hollow structural members and, more specifically, to reinforcement of hollow structures of automotive vehicles that are generally inaccessible after assembly.
BACKGROUND OF THE INVENTION
Impact resistance, fuel economy standards and structural rigidity are important fundamental concerns in automotive structural design. Fuel economy standards dictate the use of lighter materials. This usually translates into reducing the thickness of materials or using lighter weight material. Impact resistance dictates the use of thicker materials at least in localized areas. Structural rigidity also typically requires an increase of material.
The use of composite materials which are generally stronger and lighter than their metallic counterparts has increased over the years. The present inventor has pioneered a novel approach to structural part reinforcement through localized reinforcement of critical regions using microsphere-filled thermally expandable resins, such as: composite door beam which has a resin based core that occupies one-third of the bore of a metal tube; a hollow laminate beam characterized by high stiffness-to-mass ratio and having an outer portion which is separated from an inner tube by a thin layer of structural foam; a W-shaped carrier insert reinforcement which carries a foam body for use in reinforcing a hollow beam; a bulk head that utilizes a thermally expandable foam to provide localized reinforcement of a rail for the attachment of an engine cradle or the like.
Joints of an automotive vehicle are the weakest part of the structure. Stiffening the joint improves the overall stiffness in ride characteristics of the vehicle, In the formation of the automotive vehicle body, several structural/body panel members are welded or bonded together. The joints typically are hollow by their very nature. The hollow structure allows the flow of E-coat through the structural members to increase corrosion resistance. Various techniques have been used by automotive manufacturers to increase the rigidity of the joints of the vehicle. Typically, the solutions have involved substantially increasing the bulk, size and/or complexity of the joints to thereby increase rigidity. By increasing the bulk of the joints, precious packaging space has been reduced. Also, the weight of the structure due to its bulk has been increased.
SUMMARY OF THE INVENTION
It is therefore one object of the invention to reinforce a joint of an automotive vehicle without having to increase the amount of sheet metal required in the joint.
In one aspect, the present invention provides a carrier portion having an outer surface. The outer surface has a plurality of extensions that conform to the joint into which the joint reinforcement is to be placed. An adhesive layer is disposed on the outer surface of the carrier portion. The outer surface is substantially covered by the adhesive layer. The adhesive layer is formed of a thermally expandable resin material.
In another aspect, the invention provides a method of forming a reinforcement member. The method comprises the steps of providing a carrier portion; applying a layer of adhesive material to the carrier portion; heating the carrier portion and the adhesive portion; and bonding the adhesive portion to the structural member.
In yet another aspect, the present invention provides a method of forming an automotive body having at least two body members. The assembly of the body members defines a hollow space therebetween. The method includes the steps of forming a reinforcement member by applying a layer of adhesive material to a carrier portion; inserting the reinforcement member in the hollow space; and heating the body members and the carrier portion with the adhesive layer so that the adhesive material bonds to the body members.
One advantage of the present invention is that a reduced packaging space can be provided for the body members. This is in part due to the fact that a lower gauge sheet metal may be utilized in all the body members since the structural joints have been reinforced. This results in a desirable overall reduction in weight of the automotive vehicle.
REFERENCES:
patent: 5575526 (1996-11-01), Wycech
patent: 5720510 (1998-02-01), Daniel et al.
patent: 5806919 (1998-09-01), Davies
patent: 5885494 (1999-03-01), Venkataraman et al.
patent: 5915781 (1999-06-01), DeRees
patent: 6068424 (2000-05-01), Wycech
patent: 6135542 (2000-10-01), Emmelmann et al.
patent: 19603098 (1997-03-01), None
patent: WO 9743501 (1997-11-01), None
Browne Lynne H.
Harper Stephen D.
Henkel Corporation
Jaeschke Wayne C.
Pezzner Harold
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