The specific embodiment
The present invention is based on provides a kind of improved system, the sealing of the one or more members that are used to manufacture a product, buffering or reinforcing.Go for various manufacturing a product although imagine this system, such as aircraft, steamer, building, furniture or similar articles, special discovery, this system is useful for motor vehicles.Therefore, system of the present invention generally comprises one or more following contents:
1) the manufacture a product structure (for example corbeling) of (for example motor vehicles), this structure optimization ground has one or more walls that limit cavity at least in part;
2) limit the porous container of interior open space at least in part, this porous container has one or more apertures, is used to constitute this interior open space and is communicated with fluid between this container surroundings; With
3) be arranged in expandable material in the porous container interior open space, wherein container and expandable material are positioned near the structure (for example at cavity), touch this structure (walls of for example one or more qualification cavitys) so that this expandable material expands.
With reference to Fig. 1-4, the system 10 of a typical preferred embodiment that constitutes according to the present invention shown in the figure.Provide this system 10 to be used for illustrating the present invention.Estimate that the parts of system 10 among those Fig. 1-4 and the alternative of aspect also can adopt in practice of the present invention.Disclosed some such alternatives below, yet those skilled in the art will be appreciated that, equally also can adopt many other alternatives in practice of the present invention.
System 10 generally comprises porous container.The typical porous container 12 that limits interior open space 16 at least in part shown in Figure 1.This container 12 comprises at least one aperture 20, but preferably include a plurality of apertures 20, is used to constitute interior open space 16 and is communicated with fluid between container 12 ambient, external environment.
Shown in the specific embodiment, this container 12 is configured to case, it has i.e. first end wall 24 in top, bottom i.e. second end wall 26 and a plurality of (for example four) extends in the sidewall 28 between roof 24 and the diapire 26.Each shown wall 24-28 is rectangle basically.Roof 24 and diapire 26 be basically continuous be atresia, to extend in side be between top and the sidewall base and aperture 20 is configured to elongated slit.Roof 24 is made of lid that can opening and closing at least in part.
Shown in container 12 constitute for the material of rigidity relatively.This material is preferably thermosetting or thermoplastic, and that is to say (for example paints or coating processes) in automobile making can bear the temperature of use.A kind of preferred material is a polymeric material, such as polyamide (for example nylon 6,6).Advantageously this material can use various technology to process, and forms container 12 as molding (for example compression molding, injection-molded, blowing, gas is injection-molded or other similar approach), extruding or other technologies.
Although shown in container 12 be considered to be used for preferred container of the present invention, in advance can be with within the scope of the invention in respect of the container of various replacements structures.According to initial situation, this container can be configured as desirable or required shape according to the container intended purpose.For instance, this container can be designed as angle, shape, profile or other similar type, and its angle, shape, profile or other similar type with the predetermined adjacency of container or therein manufacture a product structure or its cavity is corresponding.In other words, this container can be shaped like this, and promptly it can place near various shaped element or the cavity or wherein.
As a typical alternative embodiment, container can be essentially tubular, the sidewall that it has roof, diapire and extends between roof and diapire.Preferably, roof and diapire are essentially spherical (for example circular, oval, avette or other analogous shape), and sidewall is essentially annular.Equally preferably, although do not require, when sidewall preferably includes one or more aperture (for example vertically extending slit), roof and diapire be continuous be atresia.
And estimate that this container can be made by various materials, it can be flexible, semirigid or rigidity.For instance, this container can be made by polymeric material, metal (for example aluminium, steel, magnesium, its synthetic or other metalloid), fabric, fibrous material, its synthetic or other analog.Can constitute exemplary polymeric materials (for example thermoplastic, rubber, thermosets or other analog), fabric or other analog of sheet material, comprise but do not limit polyester, polypropylene, polyamide, polyethylene, polyvinyl chloride, polyethylene, its synthetic or other similar material.
Especially for flexible or semirigid material, estimate that entire container or its part can be made of flexible wall, so that this container can be adapted to or the wall and the profile of the member that is fit to manufacture a product.In an example, the porous bag (for example mesh bag) with a plurality of apertures (for example through hole) is used as this container.In another example, container comprises rigidity or semirigid diapire and/or roof, these walls be basically continuous be atresia, and flexible porous material (for example fabric) comprises one or more sidewalls that are used for carriage.
In one embodiment, the material of container preferably can bear the temperature (for example baking oven or electroplating bath temperature are handled in electropaining as further described herein (e-coat) or japanning) of motor vehicles processing and without any distortion or any basically distortion.Yet in another embodiment, the material of container can constitute distortion or yielding under said temperature.For example, estimate under said temperature or other temperature the elongation that may maybe can become of this material, and the expansion of expandable material can cause this elongation.
In case this container is set, expandable material is preferably inserted in this container, thereby be configured for cushioning, sealing and/or reinforce the member that manufactures a product.As seen from Figure 2, the bead 30 of a plurality of expandable materials is placed in the open spaces 16 of container 12, constitutes this member 32.Preferably, to pass through from this aperture 20 even as big as preventing them when being solid-state basically when these beads 30 at least.Advantageously the expandable material of Gong Geiing often is the bead form, makes needn't further process expandable material.Certainly, estimate if necessary or requirement can be processed expandable material.
In the embodiment of any disclosure, estimate that one or more structures can be placed in the open spaces of container, thereby make expandable material needn't fill the space of as much.For example Fig. 4 illustrates the hollow structure 34 as the plastics tubular construction, and this structure is inserted in the drum ladle 36.Preferably, the bead 38 with expandable material is arranged to around the structure 34 of while in container 36.
When expandable material was configured to as shown in Figure 2 bead, this expandable material can be inserted in any container of the various not isomorphism types of the present invention.For example this expandable material can be arranged to single block or a plurality of block, and these blocks each other can be identical, also can be different.
Preferably, this expandable material is the heat-activated materials with foam characteristic.This material is dried to usually and can touches or be clamminess, and can any required pattern, position or thickness form insert this receptacle or near.Typical expandable material comprises the L﹠amp by Michigan State Romeo; The L-5248 that L Products Co., Ltd has bought, L-7002 and L-5204 foam.
Although other heat-activated materials can be used as expandable material, preferred heat-activated materials is an expansion plastic, preferably then is foamed plastics.Particularly preferred material is sealing, buffering or the sound-absorbing foam of epoxy radicals and EVA (ethylene-vinyl acetate) based structures.For example but do not limit, structural foam can be an epoxy-based material, comprises the ethylene copolymer or the trimer that can have α-alkene.As copolymer or trimer, polymer is made up of two or three different monomers, can to similar molecular linkage and little molecular composition with high chemical activity.
Known in the art have numerous reinforcings, sealing and/or buffering foam and can be used to produce foam.Typical foam comprises polymeric based material, for example epoxy resin, polyvinyl, acrylates and/or acetate base material or its synthetic, when it mixes with suitable component (generally being blowing agent and curing agent), applying heat or producing under the condition of particular surroundings, just reliably to expand and to solidify with the mode of expecting.From the chemical standpoint of heat-activated materials, structural foam usually before curing initial manufacture become flowable thermoplastic.This material with crosslinked, can not further flow this material when solidifying.The example of preferred foams component is EVA base and epoxy-based material, and they can have been bought from the market, and it is the L﹠amp of Michigan State Romeo; L Products Co., Ltd produces, and the trade mark is L5206, L5207, L5208, L5209, L5218, L5224, L5248, XP321 and XP721.These preferred foam are that this preferred material can be processed in many ways than an advantage of prior art material.These preferred materials can be by injection-molded, extruding, compression molding, apply, granulate or other similar processes with small-sized injecting and applying machine (miniapplicator).Make the structure of partial design and creative work surpass the performance of most prior art material like this.In a preferred embodiment, structural foam (in its its uncured state) normally dry or contact inviscid relatively.
Although disclosed the preferred material that is used to make expandable material, but this material can be made by other material, its condition be the material selected be thermal activation or other by environmental condition (for example humidity, pressure, time or other conditions of similarity) activation, and select under the felicity condition that applies with expection and reliably mode solidify.A kind of like this material is an epoxy, and it is disclosed in U.S. Patent No. 6,131, and in 897, patent assignee was filed an application in United States Patent and Trademark Office on March 8th, 1999, and this patent guidance content is hereby incorporated by.Some other material that may use includes, but are not limited to polyolefine material, have the copolymer of at least one monomer type α-alkene and trimer, phenol/formaldehyde materials, phenoxy group material and polyurethane material with high glass transition temperature.Also can be referring to United States Patent(USP) Nos. 5,766,719; 5,755,486; 5,575,526 and 5,932,680, (being incorporated herein by reference).Usually, expandable material preferably has good anti-corrosion, even more ideal in addition expandable material comprises one or more acrylates, one or more acetate or its synthetic, this material is disclosed in the U.S. Provisional Patent Application sequence number 60/482 of application on June 26th, 2003, in 897, for practical application is hereby incorporated by.
At expandable material is the use occasion of thermal activation, hot expandable material, and relating to the major issue of selecting and form the material that contains foam to consider is the temperature that material reacts or expands and may solidify.For example, in most of use occasions, do not wish that material at room temperature or under other production line environment temperature reacts.More typically, expandable material becomes under higher processing temperature and has activity, such as in the automobile assembly plant, when foam is at high temperature processed with automobile component or in higher external energy level, for example will be run into this situation during the preparation process that sprays paint.The temperature that runs in the automobile assembling operation may be between about 148.89 ℃ to 204.44 ℃ when (about 300 are to 400 ), and vehicle body and painting workshop are used and be about 93.33 ℃ (about 200 ) or higher usually.If desired, the blowing agent activator can join in this component, makes different temperatures beyond the above-mentioned scope cause and expands or expand with different speed or different degree.
Usually, the expanded foam of Shi Heing has about 0 to the range of expansion that surpasses 1000%.The dilation of expandable material can be increased to 1500% or higher.Also have in addition among the embodiment, estimate that expandable material may be expanded at least 2000%, 2500%, 3000% or higher with respect to former beginning and end dilation dimension.In general, obtain intensity, then obtain buffering and/or sound-absorbing by higher expansion from product with low bulk.
In another embodiment, expandable material is provided as encapsulation or part packing forms, and it can comprise bead, and this bead contains swelling foam material, and encapsulation or part are encapsulated in the housing of adhesion.A kind of like this example of system is disclosed in common special use and is not total in the US application serial No. 09/524,298 (" inflatable preform plug ") of determining, and is hereby incorporated by.
In addition,, also can use the preformed pattern to make by extruded sheet (have flat or profiled surface), carry out die-cutly then according to the container of selecting or structure according to predetermined configuration, apply it to the there again as those as noted earlier.
It will be appreciated by those skilled in the art that, a part or vehicle structure strengthening system that this system can be used as traditional resistance sound dividing plate use or are used in combination with it, for example being disclosed in common special use is not total in the US application serial No. 09/524,961 or 09/502,686 of determining (being hereby incorporated by).
Member (container that promptly has expandable material) is assembled into to generally comprise on the structure arranges and/or fixedly on the member of proximity structure.After this, expandable material activation is expanded, and at least a portion expandable material passes one or more apertures of container when expanding, and makes with the one or more surfaces or the wall of this structure to contact.In when cooling, the expandable material cures of Peng Zhanging and make container and expandable material bonds or is attached on one or more surfaces or the wall at this moment.
In Fig. 3, member 32 is placed in the cavity 50 that is limited by automobile stand column structure 52 one or more walls, construction system 10.In the embodiment shown, member 32 is at first inserted the bottom of cavity 50, make roof and diapire 24,26 with respect to one or more walls of structure 52 be vertical or vertical substantially (be that perpendicularity is within 30 °, more preferably in 20 °, very preferably in 10 °).Certainly, estimate that one of sidewall 28 or roof 24 can at first insert in the cavity 50, make member 32 be arranged in the cavity in addition.
Shown in member 32 be fixed in the cavity 50 to structure 52 walls that limit cavity 50 by container 12 interference engagement.Yet in the embodiment that replaces and according to this container 12 and structure 52, these member 32 possibilities at least temporarily adopt various technology to be attached to or abutment structure.For example, but be not limited to adopt securing member (for example screw, rivet, flechette-type securing member, binding agent, magnet, interference engagement securing member, link up with, push pin or other securing member) that member 32 is fixed on respect to this structure desired location.
When activation, bead 30 expansions, the combination of expandable material also passed aperture 20, makes it touch one or more walls of structure 52.When cooling, expandable material adheres on the wall, thereby container and expandable material are fixed in the cavity 50.Preferably, expandable material, container 12 or both cross over the entire cross section of this cavity 50 basically, therefrom pass to prevent material.
Although the expandable material that has illustrated is made of single basically basic homogeneous material, estimate to adopt various expandable material.For example, container part open spaces can be filled the higher material of expansion rate (for example being at least about 1000% expansion rate), and the adjacent part of container open spaces (for example being higher or lower than the part of initial protion) can be filled the reinforcement material of expansion rate lower (for example being lower than 1000% expansion rate).Thereby constitute a kind of system, to reach basic acoustic damping and basic the reinforcing.
With reference to Fig. 5 A and 5B, shown in the figure according to the exemplary container 100 of another suitable construction system of the present invention.This container 100 comprises first wall 102, and itself and second wall 104 are opposed and preferably substantially parallel.Peripheral wall 108 extends in the neighboring of first and second walls 102,104, makes the first wall 102 and second wall 104 separate like this.Preferably, the width (W) of this peripheral wall 108 of between is greatly between 0.1cm and 5cm, more preferably greatly about 0.3cm between the 2cm, and very preferably greatly about 0.6cm between the 1.2cm, make the first wall 102 and second wall 104 separate like this and be about width (W).First wall 102, second wall 104 and peripheral wall 108 jointly limit interior open space 114 basically.
In the embodiment shown, each wall 102,104,108 comprises a plurality of apertures 118,120,122 (for example through hole) respectively, and these apertures extend between open spaces 114 and container 100 surrounding environment 126.Preferably, the distance that each aperture 118 of first wall 102 separates each other is greatly between 0.3cm and 10cm, more preferably greatly between 0.6cm and 5cm, very preferably greatly between 0.8cm and 2.0cm.In addition preferably, each aperture 120 of second wall 104 also separates each other as the same distance that first wall 102 apertures 118 are proposed.The distance that the aperture 122 of peripheral wall 108 preferably separates each other is greatly between 0.1cm and 5cm, more preferably greatly between 0.3cm and 2cm, very preferably greatly between 0.6cm and 1.2cm.
Aperture 118,120,122 preferably have big about 0.1cm to the diameter between the 2.0cm, more preferably greatly between 0.2cm and 1.0cm, and very preferably greatly between 0.3cm and 0.5cm.Here employed term diameter means to cross over to extend in respect to a plurality of apertures 118,120,122 and is basically parallel to the maximum sized any distance in aperture on the wall that limits the aperture or the member direction.
As described here, this open spaces is preferably to small part or filling expandable material basically.This expandable material can be provided as bead, monomer material or other described form here.Expandable material can be molded in container 100 around the expandable material or by after container 100 moulding material being inserted open spaces 114 interior (for example, container 100 is made of two or more parts and can be fastening mutually) here and be fixed in the open spaces 114.
In order to constitute a kind of system (for example buffer system) according to the present invention, container 100 and expandable material are inserted in the cavity of structure (for example pillar construction) to be similar to the mode (for example, interference engagement or fastening) that container 12 is described among the correlation diagram 1-4.The container 100 of Fig. 5 A and 5B preferably places structure, makes peripheral wall 108 opposed and corresponding with the wall of structure.Thereby when expandable material activated, this expandable material expanded and flows through the aperture 122 of peripheral wall 108, with the wall of contact structures.When solidified, this expandable material preferably adheres to container 100 the due position of wall of structure.But also preferably this expandable material flows through the aperture 118,120 of first and second walls 102,104, to form foam coating on wall 102,104 one of them or boths' outer surface.
With reference to Fig. 6 A and 6B, another kind of container 130 shown in the figure, it has the configuration that is similar to container 100 among Fig. 5 A and the 5B.This container 130 comprises basically the peripheral wall 134 identical with peripheral wall 108 among Fig. 5 A and the 5B.Peripheral wall 134 and first wall 136, second wall 138 and inwall 140 constitute peripheral tubular structure 146.Peripheral wall 134 and first wall 136 and second wall 138 comprise aperture 150,152,154 respectively, their arrange and the mode of size setting basically with Fig. 5 A and 5B in basic identical to the peripheral wall 108 and first and second walls, 102, the 104 described modes of container 100.
Cross over wall 160 and cross over the interior zone of tubular structure 146 basically continuously, wherein, this zone and wall 160 are surrounded basically by tubular structure 148.Certainly, this leap wall 160 can be discontinuous because it also crosses over this zone, and tubular structure 146 can only be partly around crossing over wall 160.
Expandable material can be located in the open spaces 148 of container 130, and the container 130 of Fig. 6 A and 6B can be inserted in the structure the same manner that container among Fig. 5 A and the 5B 100 is described, and the same way as activation that expandable material can be described container among Fig. 5 A and the 5B 100 is basically expanded and flowed this material and container 100 are sticked to the appropriate location.Should be noted that additional expandable material can place on the leap wall 160 of container 130, to reach the raising of buffering and sound-absorbing.
With reference to Fig. 7, another alternative embodiment of the present invention is shown also among the figure.As shown in the figure, container 170 is made of porous fabric or flexible material (for example fabric, mesh fabric, porose fabric or other analog) thoroughly, and its bead 174 with expandable material is surrounded basically.Securing member 178 (for example threaded fastener, mechanical interlocking securing member or other similar securing member) is fixed on this container 170.Preferably, securing member 178 runs through porous container, makes this securing member help to keep this container to surround a plurality of beads.
In order to constitute according to system of the present invention, container 170 is fixed on the interior appropriate location of structural cavities with bead 174 usefulness securing members 178.In such embodiments, securing member 178 directly is fixed on the structure or can be fixed on other parts of manufacture a product (for example motor vehicles).Expandable material can activate the aperture 182 of expanding and flowing through container 170 subsequently, makes the wall of contact and moistening structure.When solidified, this expandable material is bonded to self and container 170 on the wall of structure.Preferably, the cavity of expandable material and container 170 hermetically-sealed constructions stops material therefrom to pass and/or constitute acoustic damping in this structure and cushions.
Usually, for various embodiment of the present invention, wall of a container or material, the wall or the material that particularly have the aperture will have bigger carry-over factor (transmittance), make expandable material can more easily flow through the aperture.Here employed term carry-over factor refers to the size in aperture with respect to the wall of a container that limits those walls or the size of material.Particularly this carry-over factor percentage is to allow expandable material therefrom to pass through the area size in aperture with respect to the wall that stops expandable material or the area size of material.Therefore, for example have wall on the spot face that runs through 50% wall and will have 50% carry-over factor.Wall of the present invention or material typically will be considered at least 40% carry-over factor, at least 60% carry-over factor more typically, at least 80% carry-over factor very typically, and at least 90% carry-over factor further typically.
The actual openings of container can be less or bigger, to constitute less or bigger circulation area.Circulation area used herein is can be by the minimum planes area in aperture according to the expandable material of the whole qualification of container.Exemplary circulation area typically is at least 1mm
2Or littler, more typically be at least 3mm
2, and very typically be at least 5cm
2, and typically less than 10cm
2, more typically less than 5cm
2, and very typically less than 2cm
2
Except as otherwise noted, the size of various structures described herein and geometry should not be subjected to restriction of the present invention, and other size or geometry all are possible.Can constitute a plurality of structure members with single overall structure.Another kind method is that single overall structure also can be divided into a plurality of independent parts.In addition, although described characteristics of the present invention in the scope only in the embodiment shown, for this characteristics of any given application occasion can combine with one or more other characteristics of other embodiment.Will be appreciated that the same formation of manufacturing of unique texture here and operation thereof method of the present invention in addition from above.
Here the preferred embodiments of the present invention have been disclosed.Yet those of ordinary skill in the art ought to recognize, can do certain modification in the scope that the present invention instructed.Therefore, should consider that following claim determines true scope of the present invention and content.