CN107810108A - 局部面板加强件 - Google Patents

局部面板加强件 Download PDF

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Publication number
CN107810108A
CN107810108A CN201680027916.3A CN201680027916A CN107810108A CN 107810108 A CN107810108 A CN 107810108A CN 201680027916 A CN201680027916 A CN 201680027916A CN 107810108 A CN107810108 A CN 107810108A
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CN
China
Prior art keywords
matrix material
carrier
deposit
described matrix
expansion
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.)
Pending
Application number
CN201680027916.3A
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English (en)
Inventor
基斯·马道斯
大卫·可塞
定·克瓦德勒
马克·科尔德伦
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.)
Ze Feross Ltd
Zephyros Inc
Original Assignee
Ze Feross Ltd
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 Ze Feross Ltd filed Critical Ze Feross Ltd
Publication of CN107810108A publication Critical patent/CN107810108A/zh
Pending legal-status Critical Current

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    • B32B5/02Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022Non-woven fabric
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1403Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the type of electromagnetic or particle radiation
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    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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Abstract

一种装置(10),所述装置包括载体材料(14)和基体材料(12),所述基体材料以在各个基体材料沉积物之间留出预定量的空间(18)的模式沉积在所述载体材料上。

Description

局部面板加强件
技术领域
本教导总体上涉及包括基体材料和载体材料的增强构件。
背景技术
汽车行业正在着力减少车辆总重量,以便获得改进的燃油效率。减少车辆重量的一种常见方式是减少金属板的厚度。经常地,形成车辆罩壳的车辆区域将由较薄的规格金属制成。这些车辆罩壳包括车门、后备箱、引擎盖和举升门。特别感兴趣的一个区域是车辆车门。用于车门的金属的厚度足够薄,使得其即使在最小的压力下也非常容易弯曲。为了防止这种弯曲,通过使用热固性面板加强件来增加车门的选定区域的局部刚度。这些面板加强件通常是用环氧树脂基体增强的玻璃。但是,随着金属的规格继续变薄,这些典型的面板加强件导致薄金属变形(通常称为通破(read-through))。因此,需要一种改进的面板加强件,其为金属薄板提供刚度,但不会导致金属的变形。
发明内容
在第一方面,本教导设想了一种装置,所述装置包括载体材料和基体材料,所述基体材料以在各个基体材料沉积物之间留出预定量的空间的模式沉积在所述载体材料上。
每个基体材料沉积物的直径可以是至少约0.5mm且直径小于约10mm。所述装置可以是柔性的(例如,能够容易地弯曲而不会断裂)。所述装置在握住其端部时可能因其自身重量而弯曲。所述基体材料可以是可活化材料,并且所述基体材料的体积活化是至少约100%且小于约300%。所述基体材料可包括结构粘合剂材料。所述基体材料可包括密封剂材料。每个基体材料沉积物的直径可以是至少约1mm且直径小于约4mm。所述载体可以没有任何尖角,并且只包括圆角。各个基体材料沉积物之间的预定量的空间可以是至少约0.5mm,至少约1mm,至少约2mm或甚至是至少约5mm。所述装置可包括弹性材料,所述弹性材料以在各个弹性材料沉积物之间留出预定量的空间的模式沉积在所述载体材料上。所述基体材料和所述弹性材料可以按交替模式沉积在所述载体上。
本文的教导进一步提供了一种装置,所述装置包括载体材料和基体材料,所述基体材料沉积在所述载体材料上并且旨在与金属板表面直接接触,其中,所述基体材料的热膨胀系数与所述金属板的热膨胀系数基本相同。
所述金属板可以是钢。所述热膨胀系数可以是至少约5×10-6m/mK。所述热膨胀系数可以是至少约10×10-6m/mK。
本文的教导设想了一种用于利用基体材料和相关载体进行主体结构增强的装置,由此所述基体材料以在基体材料的沉积物之间具有空间的模式进行沉积。本文公开的装置可以考虑到面板的有效增强,同时基本上不产生面板的变形。
附图说明
图1示出了根据本教导的装置的说明性示例的俯视图。
图2示出了根据本教导的装置的说明性示例的俯视图。
图3示出了根据本教导的装置的说明性示例的俯视图。
图4示出了根据本教导的装置的说明性示例的俯视图。
图5示出了根据本教导的装置的说明性示例的俯视图。
具体实施方式
本文所提供的说明和图示旨在使本领域技术人员熟悉本教导、其原理及其实际应用。本领域技术人员可以以其多种形式来适应和应用教导,因为这可能最适合于特定用途的要求。因此,所阐述的本教导的具体实施例并不旨在是穷举的或是限制本教导。因此,本教导的范围不应参照上述描述来确定,而是应该参考所附权利要求书以及这些权利要求的等同物的全部范围来确定。所有文章和参考文献(包括专利申请和出版物)的披露通过引用结合在此。还能够从以下权利要求中得到其他组合,这些组合也通过引用结合在此书面描述中。
本申请要求2015年5月14日提交的美国临时申请号62/161,523以及2015年5月20日提交的美国临时申请号62/164,224的申请日的权益,这些申请的内容出于所有目的通过引用结合在此。
本文描述的装置包括载体以及沉积在所述载体上的基体材料。载体和基体材料两者的性质使得它们可易于应用于非常薄的规格金属部件,同时避免在金属部件的表面(例如A级表面)上的通破。基体材料沉积物之间的空间对于避免通破是必不可少的,因为如果基体材料要作为整板应用到薄规格金属部件上(例如在其间没有空间的恒定板材中),则基体材料的活化可能会导致通破。
所述基体材料可以仅位于载体的一个表面上。所述装置因此可能不能将两个表面结合在一起。所述装置可以形成为使金属面板具有局部刚度的贴片。
所述基体材料可以以任何形状或模式定位在载体上,使得在各个基体材料沉积物之间存在预定空间。所述基体材料可以沉积成可具有圆形边缘的小块。所述小块的大小可以是一致的,或者可以沿着载体而变化。所述基体材料可以沉积成条带,其中各个条带之间的距离可以沿着载体是一致的。可替代地,每个条带之间的距离可以沿着载体而变化。所述条带可以全部朝向一个方向沉积,使得这些条带相互平行。所述条带可以沉积而使得第一个条带可以与第二个条带斜交地或甚至成垂直关系地定位。所述载体可以包括单个基体材料沉积物或多个基体材料沉积物。
本发明的基体材料可以是环氧基材料,并且在活化时可以是可活化的以形成环氧基粘合剂材料。所述基体材料至少可以在室温(例如约23℃)下是部分粘性的,并且还可以在约0℃至约80℃的温度下是粘性的。所述基体材料可以可替代地在室温下触摸是干燥的。此外,所述基体材料优选地展现出增强特性(例如赋予其所在的构件刚性、刚度、强度或其组合)。还优选的是,所述基体材料(通过热、UV光、感应加热等)进行活化以膨胀或以其他方式活化并且润湿与基体材料接触的表面。在活化之后(其可以包括或不包括膨胀),所述基体材料优选地固化、硬化并粘附在其接触的表面上。为了应用的目的,经常优选的是所述基体材料展现出柔性,特别是当所述基体材料被应用到车身的轮廓表面上时。然而,一旦应用,通常优选的是所述基体材料可活化以软化、膨胀(例如发泡)、固化、硬化或其组合。例如但不限于,典型的基体材料将包括聚合物材料,如环氧树脂或乙烯基聚合物,其在与合适的成分(通常为发泡剂和固化剂)混合时、在施加热量或出现特定环境条件时以可靠的、可预测的方式进行膨胀和固化。从热活化材料的化学观点来看,所述基体材料可以在固化之前作为可流动材料进行初始处理。此后,所述材料优选地在固化时交联,这样使得所述材料基本上不能进一步流动。
环氧树脂可以是脂族的、脂环族的、芳族的等等。环氧树脂可以作为固体(例如作为丸粒、大块、碎片等)或液体来供应。环氧树脂可以包括可具有α-烯烃的乙烯共聚物或三元共聚物。作为共聚物或三元共聚物,所述聚合物由两种或三种不同的单体构成,所述单体即能够与类似分子连接的具有高化学反应性的小分子。一种示例性环氧树脂可以是酚醛树脂,其可以是酚醛型或其他类型的树脂。其他优选的含环氧树脂材料可以包括双酚A环氧氯丙烷醚聚合物,或可以用丁二烯或另一种聚合物添加剂改性的双酚A环氧树脂。可以用在基体材料中的合适的环氧基材料的实例以产品标示L5020、L5010、L5224、L8000、L5001进行销售,并且可以从L&L Products公司(Romeo,Mich)购得。根据优选的配方,基本材料可以包括最多达按重量计约50%的环氧树脂,更优选地最多达按重量计约65%的环氧树脂,甚至更优选地最多达按重量计约80%的环氧树脂。
有利地,本发明的基体材料可以用各种方式形成或以其他方式加工。例如,优选的基体材料可以通过注射成型、挤出、模压成型或用机器人控制的挤出机(如微型涂布机)进行加工。受控的挤出机可以允许精确放置一种或多种基体材料和弹性材料。
所述弹性材料可以是对金属板提供振动阻尼的材料。类似于基体材料,弹性材料还可以是可活化的并且能够膨胀。
基体材料和/或弹性材料可以被配制成具有所需的热膨胀系数。这种热膨胀系数可以被选择为使得其类似于在使用所述装置期间施加基体材料的金属的热膨胀系数。可以具体地选择填充材料以帮助使基体材料的热膨胀系数与金属板的热膨胀系数匹配。
用于接收基体材料的载体材料可以是玻璃材料(例如玻璃纤维材料),其可以是玻璃网状材料。所述载体可以包括非导电线或丝(例如长丝、纤维或织物材料),其可以用作垫、布、粗纱、网格、网状物、稀松布等。在这样的实施例中,所述载体材料可以由例如棉织物的织造或非织造纤维、长丝等、玻璃(例如E-玻璃或S-玻璃)、玻璃纤维,聚酯薄膜、尼龙、聚酯、碳、芳族聚酰胺、塑料、聚合物(例如热塑性塑料,如聚酰胺(例如尼龙)、PET(例如聚酯薄膜)、聚碳酸酯、聚乙烯、聚丙烯、聚丁烯(例如聚对苯二甲酸丁二醇酯)、聚苯乙烯、聚氨酯、乙烯基或它们的任何组合)或其他材料。如本文所使用的,“线”或“丝”意味着材料的单个细丝、编织的细丝束或者未编织的细丝束。所述载体材料可以是铝。所述载体可以包括金属材料。所述载体可以明显地比任何薄膜材料厚。所述载体可以不含任何薄膜材料。所述载体可以是基本上刚性的,或者可以具有最小量的柔性。所述载体可能不如薄膜材料柔软。
可以理解的是,网状材料可以是珠状颗粒、聚集物、中空材料(例如中空颗粒)或其他方式或其任何组合。在这样的实施例中,所述加强材料可以由例如玻璃(例如E-玻璃或S-玻璃)、玻璃纤维、尼龙、聚酯、碳、芳族聚酰胺、塑料、聚合物(例如热塑性塑料,如聚酰胺(例如尼龙)、聚碳酸酯、聚乙烯、聚丙烯、聚丁烯(例如聚对苯二甲酸丁二醇酯)、聚苯乙烯、聚氨酯、乙烯基或其任意组合)或其他材料。
图1示出了具有基体材料12的装置10。载体14位于与基体材料层12平面接触的位置。载体14和基体材料12形成为具有弯曲拐角16。
图2示出了包括载体14的装置10,所述载体具有沉积在所述载体上的多个基体材料部分12。多个空间18位于基体材料12之间。
图3示出了包括载体14的装置10,所述载体具有沉积在所述载体上的多个基体材料部分12以及沉积在所述载体上的多个弹性材料部分20。多个空间18位于基体材料12与弹性材料20之间。
图4示出了包括载体14的装置10,所述载体具有沉积在所述载体上的多个基体材料部分12。多个空间18位于基体材料12之间。
图5示出了包括载体14的装置10,所述载体具有基本上直线地沉积在所述载体上的多个基体材料部分12。多个空间18位于基体材料12之间。
本文公开的装置使薄规格金属面板具有另加的刚度、而没有与通破有关的问题。通过在可活化材料沉积物之间提供空间而基本上避免了通破问题。通过提供具有弯曲边缘的载体(例如基本上没有任何直角(或接近直角)的载体)而进一步避免了问题。所述装置优选地仅在所述载体的一个表面上形成为具有基体材料。基体材料沉积物可以基本上小于所述载体的全部覆盖范围。
本文所述的任何数值包括以一个单位的增量从较低值到较高值的所有值,条件是在任何较低值和任何较高值之间存在至少2个单位的间隔。作为示例,如果阐明成分的量或过程变量(诸如例如温度、压力、时间等)的值例如为1-90,优选地为20-80,更优选地为30-70,则在本说明书中明确列举了值15至85、22至68、43至51、30至32等。对于小于1的值,根据需要认为一个单位是0.0001、0.001、0.01或0.1。这些仅是特定地预期的实例,并且在最低值与最高值之间的数值的所有可能组合被认为是以一种类似的方式在本申请中清楚地指出。可以看出,在本文中表示为“重量份”的量的教导也考虑了以重量百分比表示的相同范围。因此,就“按所得到的聚合物共混组合物的重量计的‘x’份”而言,本发明的详细说明中的表述也考虑了相同的表述的“按所得到的聚合物共混组合物的重量百分比计的量“x”的教导。
除非另有说明,否则所有范围均包括端点以及端点之间的所有数字。与范围相关的“约”或“近似”的使用适用于所述范围的两端。因此,“约20至30”旨在涵盖“约20至约30”,至少包括所指定的端点。
所有文章和参考文献(包括专利申请和出版物)的披露通过引用结合在此。用于描述组合的术语“基本上由...组成”应包括元件、成分、组分或步骤以及不会对组合的基本特征和新颖性特征产生重大影响的这类其他元件、组分或步骤。用于描述本文的元件、成分、组分或步骤的组合的术语“包括(comprising)”或“包括(including)”还预期了基本上由元件、成分、组分或步骤组成的实施例。通过在本文中使用术语“可以(may)”,意图是“可以(may)”包括的任何描述的属性都是可选的。
多种元件、成分、组分或步骤可以由单个集成元件、成分、组分或步骤来提供。可替代地,单个集成元件、成分、组分或步骤可以被分成单独的多个元件、成分、组分或步骤。用于描述元件、成分、组分或步骤的“一个(a)”或“一个(one)”的披露不旨在排除附加的元件、成分、组分或步骤。
应理解的是,以上说明旨在是说明性的,而非限制性的。在阅读上述说明之后,除了所提供的实施例之外,许多实施例以及许多应用对于本领域技术人员将是显而易见的。因此,本发明的范围不应参照上述描述来确定,而是应该参考所附权利要求书以及这些权利要求的等同物的全部范围来确定。所有文章和参考文献(包括专利申请和出版物)的披露通过引用结合在此。本文所公开的主题的任何方面的以下权利要求中的遗漏不是此主题的免责声明,也不应被认为是发明人不认为这样的主题是所公开的发明主题的一部分。

Claims (20)

1.一种装置,包括:
载体材料;
基体材料,所述基体材料以在各个基体材料沉积物之间留出预定量的空间的模式沉积在所述载体材料上。
2.如权利要求1所述的装置,其中,每个基体材料沉积物的直径为至少约0.5mm且直径小于约10mm。
3.如权利要求1或权利要求2所述的装置,其中,所述装置是柔性的(例如,能够容易地弯曲而不会断裂)。
4.如权利要求1至3中任一项所述的装置,其中,所述装置在保持在其端部时将在其自重下弯曲。
5.如权利要求1至4中任一项所述的装置,其中,所述基体材料是可活化材料,并且所述基体材料的体积式活化是至少约100%且小于约300%。
6.如权利要求1至5中任一项所述的装置,其中,所述基体材料包括结构粘合剂材料。
7.如权利要求1至6中任一项所述的装置,其中,所述基体材料包括密封剂材料。
8.如权利要求1至7中任一项所述的装置,其中,每个基体材料沉积物的直径为至少约1mm且直径小于约4mm。
9.如权利要求1至8中任一项所述的装置,其中,所述载体没有任何尖角并且仅包括圆角。
10.如权利要求1至9中任一项所述的装置,其中,各个基体材料沉积物之间的预定量的空间为至少约0.5mm,至少约1mm,至少约2mm或甚至是至少约5mm。
11.如权利要求1至10中任一项所述的装置,包括弹性材料,所述弹性材料以在各个弹性材料沉积物之间留出预定量的空间的模式沉积在所述载体材料上。
12.如权利要求11所述的装置,其中,所述基体材料和所述弹性材料以交替模式沉积在所述载体上。
13.如权利要求1至12中任一项所述的装置,其中,所述基体材料仅沉积在所述载体的一个表面上。
14.如权利要求14至18中任一项所述的装置,其中,所述载体基本上不含任何薄膜材料。
15.一种装置,包括:
载体材料;
基体材料,所述基体材料沉积在所述载体材料上并且旨在与金属板表面直接接触,其中,所述基体材料的热膨胀系数与所述金属板的热膨胀系数基本相同。
16.如权利要求15所述的装置,其中,所述金属板是钢。
17.如权利要求15或权利要求16所述的装置,其中,所述热膨胀系数为至少约5×10-6m/mK。
18.如权利要求15至17中任一项所述的装置,其中,所述热膨胀系数为至少约10×10- 6m/mK。
19.如权利要求15至18中任一项所述的装置,其中,所述基体材料仅沉积在所述载体的一个表面上。
20.如权利要求15至19中任一项所述的装置,其中,所述载体基本上不含任何薄膜材料。
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US20180111351A1 (en) 2018-04-26

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