Land vehicles: bodies and tops – Bodies – Structural detail
Reexamination Certificate
2000-01-31
2001-03-13
Pape, Joseph D. (Department: 3612)
Land vehicles: bodies and tops
Bodies
Structural detail
C296S203010, C296S146600, C428S034100, C428S906000
Reexamination Certificate
active
06199940
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 tubular carrier to provide additional localized stiffness to frames, rails, cavities and other structural members. Such a 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 in manufacturing, handling and use over prior carrier and expansible foaming reinforcing material combinations. In particular, the present invention enjoys the benefits of utilizing an initially non-tacky reinforcing composition and a carrier which readily receives the material and provides excellent load distribution.
Broadly speaking, the present invention includes a tubular carrier, a thermally expansible foaming reinforcing material for bonding to and interconnecting the carrier to a structural member, and a fastener providing mechanical attachment for holding the reinforcing material on the carrier. The tubular carrier has a continuous arcuate wall, and the reinforcing material is preferably initially non-tacky and is thermally expansible and foams, such as by internal chemical reaction or more preferably by the external application of heat. The mechanical attachment serves to inhibit relative movement between the carrier and the reinforcing material and may be variously provided, such as by a tab provided on the tubular carrier or by a separate mechanical fastener, e.g. a push pin. Passages in the reinforcing material enable the fastener to pass therethrough and to secure the reinforcing material to the carrier.
The continuous arcuate wall of the carrier promote good load distribution without excessive weight. The carrier is preferably hollow, with the reinforcing material located exteriorly on the wall. The reinforcing material may be provided alternately configured as annular rings, an elongated sleeve, or elongated prisms which aid in locating the member by their receipt in interior corners of a structural member.
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 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.
These and other advantages will be readily appreciated by those skilled in the art with reference to the drawings and the following description.
REFERENCES:
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Side view photograph of admitted prior art automobile rail reinforcing member with adhesively attached thermally expandable reinforcing material after brake-out but not shown positioned within the rail No Date.
Perspective view of admitted prior art automobile rail reinforcing member with adhesively attached thermally expandable reinforcing material after bake-out but not shown positioned within the rail No Date.
Photograph of section of admitted prior art SUV crossmember reinforcing member with adhesively attached thermally expandable material after bake-out located between metal structural parts of an automobile No Date.
Photograph of section of admitted prior art SUV crossmember reinforcing member with adhesively attached thermally epxandable material after bake-out located between metal structural parts of an automobile No Date.
Blank Norman E.
Chang Chin-Jui
Fitzgerald Gerald
Hopton Gregory W.
Stratman Randy
Hovey Williams Timmons & Collins
Pape Joseph D.
Patel Kiran
SIKA Corporation
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