CA2655942A1 - Structural reinforcement system for automotive vehicles - Google Patents

Structural reinforcement system for automotive vehicles Download PDF

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Publication number
CA2655942A1
CA2655942A1 CA002655942A CA2655942A CA2655942A1 CA 2655942 A1 CA2655942 A1 CA 2655942A1 CA 002655942 A CA002655942 A CA 002655942A CA 2655942 A CA2655942 A CA 2655942A CA 2655942 A1 CA2655942 A1 CA 2655942A1
Authority
CA
Canada
Prior art keywords
skeleton member
reinforcement
expandable material
automotive vehicle
ribs
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA002655942A
Other languages
French (fr)
Other versions
CA2655942C (en
Inventor
William J. Barz
Thomas L. Coon
Michael J. Czaplicki
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Zephyros Inc
Original Assignee
Zephyros, Inc.
William J. Barz
Thomas L. Coon
Michael J. Czaplicki
L&L Products, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Zephyros, Inc., William J. Barz, Thomas L. Coon, Michael J. Czaplicki, L&L Products, Inc. filed Critical Zephyros, Inc.
Priority claimed from CA002399457A external-priority patent/CA2399457C/en
Publication of CA2655942A1 publication Critical patent/CA2655942A1/en
Application granted granted Critical
Publication of CA2655942C publication Critical patent/CA2655942C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/001—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material
    • B62D29/002—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material a foamable synthetic material or metal being added in situ
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/04—Door pillars ; windshield pillars

Abstract

An automotive vehicle frame reinforcement system has a skeleton member (16) designed to be placed in a cavity defined in a vehicle frame, such as a roof or pillar section. An expandable material (30), such as an epoxy-based reinforcement foam, is disposed on the skeleton member (16). Once the system is attached to the frame, the foam expands and cures during an automobile assembly operation, bonding the reinforcement system to the frame. As a result, the reinforcement system provides enhanced load distribution over the vehicle frame without adding excessive weight.

Claims (55)

1. A system for reinforcement of an automotive vehicle frame, comprising:
a skeleton member configured for placement in a cavity defined in the automotive vehicle frame, said skeleton member having an axis extending along a length of said skeleton member, said skeleton member having a plurality of ribs, said skeleton member having a first cross-sectional area taken generally perpendicular to said axis at first end of said length that is less than about seventy-five percent of a second cross-sectional area taken generally perpendicular to said axis at a second end of said length, said first end generally opposite said second end; and an expandable material over at least a portion of said skeleton member, said expandable material configured to secure said skeleton member to said cavity defined in the automotive vehicle frame and provide an energy distribution in conjunction with said plurality of ribs wherein said plurality of ribs is substantially devoid of said expandable material.
2. A reinforcement system as in claim 1, wherein said skeleton member includes a first portion and a second portion extending substantially parallel to said axis, said plurality of ribs adjoining said first portion and said second portion, said plurality of ribs extending generally non-parallel to said first portion and said second portion.
3. A reinforcement system as in claim 2, wherein said plurality of ribs extend substantially perpendicular to said first portion and said second portion.
4. A reinforcement system as in claim 1, wherein cross-sectional areas taken generally perpendicular to said axis at different locations between said first and said second ends are substantially continuously variable.
5. A reinforcement system as in claim 4, wherein said axis extends generally centrally through said skeleton member and said skeleton member is substantially asymmetrical about said axis.
6. A reinforcement system as in claim 1, wherein said skeleton member is at least partially formed of molded plastic.
7. A reinforcement system as in claim 1, wherein said expandable material is substantially tack-free to the touch.
8. A reinforcement system as in claim 1, wherein said first cross-sectional area is about less than fifty percent of said second cross-sectional area.
9. A reinforcement system as in claim 1, wherein said first cross-sectional area is about less than twenty five percent of said second cross-sectional area.
10. A reinforcement system of an automotive vehicle frame comprising:
an automotive vehicle frame for a roof and pillar of the automotive vehicle, the frame having a roof rail with a plurality of wall portions defining a cavity therein, the roof rail extending longitudinally relative to the vehicle;
a skeleton member at least partially disposed within the cavity as defined by the roof rail, the skeleton member having a length and a longitudinal axis extending along the roof rail, the skeleton member comprising a first portion with a plurality of ribs and a second portion extending away from the first portion, the second portion also including a plurality of ribs, the skeleton member including a first outwardly facing surface opposing at least one of the wall portions and a second outwardly facing surface opposite the first outwardly facing surface wherein the first outwardly facing surface substantially extends along the entire length of the skeleton member; and a structural foam material in sealing contact with the skeleton member and at least one of the plurality of wall portions, wherein:
i) at least two of the plurality of ribs of the first portion are in spaced apart opposing relation to each other; and ii) the structural foam material sealingly contacts the first outwardly facing surface along substantially the entire length of the skeleton member and the structural foam material sealingly contacts the second outwardly facing surface along a substantial portion of the length of the skeleton member.
11. A reinforcement system as in claim 10, wherein the automotive vehicle frame includes a roof rail adjoining an A-pillar and the first portion of the skeleton member is located in the roof rail and the second portion of the skeleton member extends into the A-pillar.
12. A reinforcement system as in claim 11, wherein the second portion has a cross-sectional area taken generally perpendicular to the axis that is less than about fifty percent of a cross-sectional area of the first portion taken generally perpendicular to the axis.
13. A reinforcement system as in claim 10, wherein the first portion has a first cross-sectional area taken generally perpendicular to the axis at one end of the length that is less than about fifty percent of a second cross-sectional area of the second portion taken generally perpendicular to the axis at an opposite end of the length.
14. A reinforcement system as in claim 10, wherein the automotive vehicle frame includes a roof rail and wherein the first and second portions of the skeleton member are located in the roof rail.
15. A reinforcement system as in claim 14, wherein the first portion and the second portion are separated by a third portion, the third portion including a through-hole extending through a substantial amount of the third portion, the substantial amount being greater than half of the third portion.
16. A reinforcement system as in claim 10, wherein at least two of said plurality of ribs in the first portion intersect with each other and the plurality of ribs in the first portion are substantially devoid of the foam.
17. A reinforcement system as in claim 12, wherein the skeleton member and the structural foam material cooperatively seal the cavity to block passage of materials through the cavity.
18. A reinforcement system as in claim 14, wherein the skeleton member and the structural foam cooperatively seal the cavity to block passage of materials through the cavity.
19. A reinforcement system as in claim 10, wherein the first portion is contiguous with the second portion and the first portion and the second portion are substantially aligned with each other along the longitudinal axis.
20. A reinforcement system as in claim 19, wherein the skeleton member is formed as a singular molded plastic component.
21. A reinforcement system as in claim 18, wherein at least two of said plurality of ribs in the first portion intersect with each other and the plurality of ribs in the first portion are substantially devoid of the foam.
22. A reinforcement system as in claim 10, wherein at least three of the plurality of ribs of the first portion and at least three of the plurality of ribs of the second portion are in spaced apart opposing relation to each other and the at least three of plurality of ribs of the first portion each extend between the first outwardly facing surface and the second outwardly facing surface.
23. A reinforcement system as in claim 10, wherein the outwardly facing surface of the first portion and the outwardly facing surface of the second portion are coextensive with the longitudinal axis and the structural foam material is coextensive with the outwardly facing surface of the first portion and the outwardly facing surface of the second portion.
24. A system for reinforcement of an automotive vehicle, comprising:
an automotive vehicle frame, the frame having a plurality of wall portions defining a cavity therein;
a skeleton member disposed within the cavity, the skeleton member having a longitudinal axis, the skeleton member comprising a first portion intermediate a second portion and a third portion; and a structural foam material in sealing contact with the skeleton member and at least one of the plurality of wall portions, wherein:
i) the first portion and the second portion each include a at least one laterally extending rib and at least one longitudinally extending rib;
ii) the skeleton member includes a first longitudinal outwardly facing surface opposite a second outward facing longitudinal surface; and iii) the first portion includes an opening suitable for passage of a component therethrough.
25. A system for reinforcement of an automotive vehicle as in claim 24, wherein the first portion has a first cross-sectional area taken generally perpendicular to the axis that is less than about fifty percent of a second cross-sectional area of the second portion taken generally perpendicular to the axis or less than about fifty percent of a third cross-sectional area of the third portion taken generally perpendicular to the axis.
26. A system for reinforcement of an automotive vehicle as in claim 24, wherein the first portion has a first cross-sectional area taken generally perpendicular to the axis that is less than about fifty percent of a second cross-sectional area of the second portion taken generally perpendicular to the axis and less than about fifty percent of a third cross-sectional area of the third portion taken generally perpendicular to the axis.
27. A system for reinforcement of an automotive vehicle as in claim 24, wherein the longitudinal axis extends horizontally.
28. A system for reinforcement of an automotive vehicle as in claim 24, wherein the opening extends through a substantial amount of the first portion.
29. A system for reinforcement of an automotive vehicle as in claim 24, wherein the at least one laterally extending rib of the first portion intersects the at least one longitudinally extending rib of the first portion or the at least one laterally extending rib of the second portion intersects the at least one longitudinally extending rib of the second portion.
30. A system for reinforcement of an automotive vehicle as in claim 24, wherein the at least one laterally extending rib of the first portion intersects the at least one longitudinally extending rib of the first portion and the at least one laterally extending rib of the second portion intersects the at least one longitudinally extending rib of the second portion.
31. A system for reinforcement of an automotive vehicle as in claim 24, wherein the at least one laterally extending rib and the at least one longitudinally extending rib of the first portion and second portion are substantially devoid of the foam.
32. A system for reinforcement of an automotive vehicle as in claim 24, wherein the skeleton member and the structural foam cooperatively seal the cavity to block passage of materials through the cavity.
33. A system for reinforcement of an automotive vehicle as in claim 24, wherein both the first surface and second surface extending at least along the first portion and second portion of the skeleton member.
34. A system for reinforcement of an automotive vehicle as in claim 24, the skeleton member includes one or more extensions extending therefrom.
35. A system for reinforcement of an automotive vehicle as in claim 24, the plurality of walls of the automotive vehicle frame are art of a rail of the automotive vehicle.
36. A method of reinforcing a structure of an automotive vehicle, the method comprising:
molding a plastic skeleton member, the skeleton member having a plurality of ribs disposed along a length of the skeleton member wherein each of the plurality of ribs extends transverse relative to the length and the plurality of ribs are spaced a part from each other;
attaching a substantially non-tacky expandable material to the skeleton member to form a reinforcement member;
locating the reinforcement member within a cavity of the structure of the automotive vehicle; and activating the expandable material by exposure to elevated temperature to foam, cure and adhere to walls of the structure defining the cavity thereby forming a reinforced system.
37. The method of claim 36, wherein the skeleton member includes a first longitudinal outwardly facing surface opposite a second outward facing longitudinal surface and wherein both the first surface and the second surface are interconnected by the plurality of ribs and are substantially entirely covered by the expandable material.
38. The method of claim 36, wherein the step of activating the expandable material includes activating the expandable material to form a structural foam.
39. The method of claim 36, wherein the skeleton members includes at least one laterally extending rib and at least one longitudinally extending rib and the at least one laterally extending rib intersects the at least one longitudinally extending rib.
40. The method of claim 39, wherein the at least one laterally extending rib and the at least one longitudinally extending rib of the first portion and are substantially devoid of the expandable material.
41. The method of claim 36, wherein the expandable material is epoxy based.
42. The method of claim 36, wherein the step of attaching the expandable material includes molding the expandable material upon the skeleton member.
43. The method of claim 36, wherein the step of attaching the expandable material includes extruding the expandable material upon the skeleton member.
44. A method of reinforcing a structure of an automotive vehicle, the method comprising:
providing a plastic skeleton member, wherein:
i. the skeleton member includes a plurality of ribs disposed and spaced apart along the length of the skeleton member;
attaching an expandable material to the skeleton member to form a reinforcement member, wherein:
i. the expandable material is substantially non-tacky to the touch; and ii.the step of attaching the expandable material to the skeleton member includes molding of the expandable material;

locating the reinforcement member within a cavity of the structure of the automotive vehicle; and adhering the expandable material to walls of the structure defining the cavity for forming a reinforced system, wherein:
i. the step of adhering the expandable material includes activating the expandable material to foam.
45. The method of claim 44, wherein the skeleton member includes an opening suitable for passage of a component therethrough.
46. The method of claim 44, wherein the skeleton member and the structural foam cooperatively seal the cavity to block passage of materials through the cavity.
47. The method of claim 44, wherein the structure of the automotive vehicle is selected from a roof rail, a pillar or a frame member.
48. The method of claim 44, wherein the expandable material is in sealing contact with the skeleton member.
49. The method of claim 44, wherein the expandable material is epoxy based and the skeleton members includes at least one laterally extending rib and at least one longitudinally extending rib and the at least one laterally extending rib intersects the at least one longitudinally extending rib.
50. The method of claim 44, wherein the skeleton member is formed of a fiber reinforced polyamide.
51. The method of claim 44, wherein the expandable material is designed to expand in a paint or e-coat oven.
52. A method of reinforcing a structure of an automotive vehicle, the method comprising:
providing a skeleton member, wherein:

i. the step of providing the skeleton member includes injection molding the carrier to a desired shape;
ii. the skeleton member is formed of a plastic; and iii. the skeleton member includes a plurality of ribs disposed along the length of the skeleton member;
attaching a expandable material to the skeleton member to form a reinforcement member, wherein:
i. the expandable material is a heat activatable material;
ii. the expandable material is epoxy-based;
iii. the plurality of ribs is substantially devoid of the expandable material;

and iv. the expandable material is substantially non-tacky to the touch;
locating the reinforcement member within a cavity of the structure of the automotive vehicle; and adhering the expandable material to walls of the structure defining the cavity for forming a reinforced system, wherein:
i. the step of adhering the expandable material includes activating the expandable material to foam; and ii. curing the expandable material to bond the expandable material to the walls of the structure.
53. The method of claim 52 wherein the skeleton member includes one or more extensions extending therefrom.
54. The method of claim 52 wherein at least two of the plurality of ribs are in spaced apart opposing relation to each other and wherein the expandable material extends substantially continuously about a circumference of the skeleton member.
55. The method of claim 52 wherein the step of attaching the expandable material includes molding the expandable material upon the skeleton member.
CA2655942A 2000-02-11 2001-01-18 Structural reinforcement system for automotive vehicles Expired - Fee Related CA2655942C (en)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
US09/502,686 US6467834B1 (en) 2000-02-11 2000-02-11 Structural reinforcement system for automotive vehicles
US09/502,686 2000-02-11
US09/655,965 US6619727B1 (en) 2000-02-11 2000-09-06 Structural reinforcement system for automotive vehicles
US09/655,965 2000-09-06
CA002399457A CA2399457C (en) 2000-02-11 2001-01-18 Structural reinforcement system for automotive vehicles

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
CA002399457A Division CA2399457C (en) 2000-02-11 2001-01-18 Structural reinforcement system for automotive vehicles

Publications (2)

Publication Number Publication Date
CA2655942A1 true CA2655942A1 (en) 2001-08-16
CA2655942C CA2655942C (en) 2011-08-02

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Family Applications (1)

Application Number Title Priority Date Filing Date
CA2655942A Expired - Fee Related CA2655942C (en) 2000-02-11 2001-01-18 Structural reinforcement system for automotive vehicles

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US (2) US6467834B1 (en)
JP (1) JP4780634B2 (en)
CA (1) CA2655942C (en)

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US6619727B1 (en) 2003-09-16
JP2003522075A (en) 2003-07-22
US6467834B1 (en) 2002-10-22
CA2655942C (en) 2011-08-02
JP4780634B2 (en) 2011-09-28

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