CN1620362A - 加固的结构主体及其制造方法 - Google Patents

加固的结构主体及其制造方法 Download PDF

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CN1620362A
CN1620362A CNA038025841A CN03802584A CN1620362A CN 1620362 A CN1620362 A CN 1620362A CN A038025841 A CNA038025841 A CN A038025841A CN 03802584 A CN03802584 A CN 03802584A CN 1620362 A CN1620362 A CN 1620362A
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S·克罗普夫尔德
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
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    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
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    • B29C44/18—Filling preformed cavities
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

本发明涉及一种中空结构主体，如车辆的双开门车身或车架纵梁，用诸如聚氨酯泡沫塑料那样的增强材料加强，带有堵头的***件插进结构主体的一部分内，在***地点***件与结构主体结合，产生容置区，可放置增强材料。未固化的增强材料加入该容置区中再进行固化。本发明通过将增强结构，方便精确地提供到结构主体中，解决技术上的问题，具有强的碰撞强度和改进的吸音特性等。

Description

加固的结构主体及其制造方法
本发明涉及一种含结构增强材料的结构主体。具体地说，本发明涉及结构加固的、密封的和吸音的车辆车身，如加固的车架纵梁及双开门车身。
车辆的中空骨架(结构主体)常用泡沫塑料填充，以便密封，抑制噪音、赋予结构强度、刚度或吸音特性。典型做法是结构主体填充诸如聚氨酯那样的泡沫塑料，将活性剂液体放入要加强的区域(即加固区)，并让泡沫塑料起反应，填充加固区。不幸的是，该方法无法控制，各辆车辆的空腔中填充泡沫塑料多少不一。许多情况下该方法还需使用特殊的塞子塞住以免泡沫塑料漏失和堵塞作用孔，如安装其他部件的孔。
美国专利5,194,199；5,866,052及6,062,624公开另一种加强结构主体的方法，该方法将预发泡的固化泡沫塑料结构零件***结构主体。但该方法要利用可膨胀聚氨酯或环氧树脂将结构零件粘附在适当位置，而该树脂有损于零件的整体结构性能。此外，结构零件与结构主体连接的完整性可能因来固化粘合剂的烘箱不一致性而受到影响，因此希望提供的结构加强件严格放置在结构主体中，不易发生密封剂的缺陷或依赖与烘箱温度的一致性。
本发明在技术上要解决问题是提供一种有内腔的结构主体的加强方法，该方法包括以下步骤：(a)将带有堵头的***件插到结构主体的一部分内腔中并在***位置与结构主体结合，形成增强材料的容置区，该容置区还有一入口；(b)将该***件与结构主体密封；(c)通过加固区入口加进足量的未固化增强材料，至少填充一部分容置区；以及(d)使增强材料固化。
在第二方面中，本发明的增强结构主体包括：(a)有内腔的结构主体；(b)带有堵头的***件，其放在内腔中并密封，该***件在***位置与结构主体结合，形成至少部分地填充未固化的增强材料的加固区。
在第三方面中本发明的增强结构主体包括：(a)有内腔的结构主体，(b)带有堵头的***件，其位于内腔中并密封，该***件在插放位置与结构主体结合，形成至少部分填充固化的增强材料的加固区。
本发明特别适用于结构主体的增强，尤其是车辆车架纵梁及双开门车身。例如，车辆的车架纵梁有变薄区是很普遍的用于产生碰撞缓冲区，以便消散事故的能量，而保护乘客。车架纵梁还支撑着车辆的部件，如传动装置。本发明提供将增强材料有选择地加入一部分纵梁的方法，其不会有损于碰撞缓冲或堵塞其他部件，如发动机和传动装置的安装孔。本发明还可用于增强车辆的其他部件，如踏脚板、底盘梁、立柱、横杆、车身固定件。此外，本发明可用于非车辆用途，如运动器械(例如高尔夫棒)、小汽艇、自行车、飞机、卡车和火车。
图1是装有加强件的车辆双开门车身的透视图。
图2是图1所示加强件的放大剖视图。
图1示出本发明一优选实施例的实例。结构主体100是车辆的双开门车身示例，用安装接头、夹片、螺钉、柳钉、定位销、焊接头或胶合剂等***并定位在开门车身100的一部分内腔中的是带有堵头的***件110，该***件被放置在待加固区域。***件110与结构主体在***位置100a处一部分的内壁相结合，使随后注入的加强材料限制在该***件和在***位置那部分结构主体形成的区域内。因此，***件110本身并不是盛料器，但却与结构主体结合形成了可随后放入增强材料的加固区，因为：a.至少有一个与***件结合的堵头110a；b)至少一个堵头110a的界限内有结构主体内壁(在插放处包括一个现存堵头的场合***件有一个堵头是恰当的)。
在加固区内至少局部填充增强材料120，最好基本上完全填充，增强材料最好是一二组分可膨胀泡沫塑料，如可膨胀聚氨酯或可膨胀环氧树脂。
现在转向图2，图2是在一部分双开门车身100中的***件110的放大剖视图，***件110优选用密封剂130与双开门车身密封。图2还示出凸形件140，沿增强材料120方向伸展，凸形件可用任何一种适用方法，如表面成形、覆盖在孔上等保护孔口150，通常是安装孔或检修孔，不会被增强材料120堵住。
结构主体可用任何一种适用材料制造，它的选用与用途有关。例如对车架纵梁或车辆的其他圆形结构件而言，结构主体可用金属制造，如钢、铝或其合金。其它适用的材料有塑料、木材、陶瓷、复合材料、玻璃及其刚度容易形成结构主体的其它材料。
***件110可用任何一种适用的材料制造，如制造结构主体使用的材料，虽然***件110和结构主体100不必用相同材料。例如，若结构主体100是钢的双开门车身，***件100最好是塑料或用填料增强的塑料，该塑料能耐车辆制造相关的温度与应力。这种用途的适用的塑料的例子如尼龙，聚碳酸酯，聚苯乙烯，诸如聚乙烯和聚丙烯那样的聚烯烃，诸如苯酚-甲醛、苯酚-糠醛那样的热固性树脂，聚氨酯及环氧树脂。塑料最好是填料加强的热塑料性材料，如玻璃增强尼龙，市场上有VYDYNE(陶式化学公司的商标)增强树脂。玻璃增强尼龙最好是玻璃的容积含量占10％-40％。
密封剂130优选是低密度热可膨胀环氧树脂密封剂，如BETABRACE(陶式化学公司的商标)环氧树脂。但也可用非膨胀型密封剂进行密封。此外，也可用机械方法密封，例如用与安装双开门车身的形状紧密配合的弹性体***件。
增强材料120可以是能提高结构主体100的结构特性或隔音特性的任何材料。优选材料的例子包括诸如膨胀型聚氨酯和膨胀型环氧树脂那样的泡沫塑料。增强材料120最好是用诸如技术上已知的适用方法做成的聚氨酯泡沫塑料。例如，聚氨酯泡沫塑料可用美国专利4,390,645；2,866,744；3,755,212；3,849,146；3,821,130，及5,968,995中所述任一种方法制造。
加固的结构主体的优选制备方法包括将有堵头的***件插进结构主体的内腔一部分中并使其固定；***件与结构主体在***位置结合，形成加固区。对本发明的目的而言，加固区是要求加固区域构成的内腔。
附加的***件然后热密封到结构主体上，以便将增强材料限制在加固区范围内。增强材料最好是未固化的双组聚氨酯树脂，通过入口加入到加固区内，该树脂可以是原有的或现生产的，至少填充一部分加固区，更优选基本上完全填充加固区。然后对增强材料用化学或加热方法固化，最好是化学方法。
***件的制备可用各种技术，包括注塑、吹塑、冲压，注塑最好。***件最好注塑成相对的又可连接的两半，扣合后再附加到结构主体中。
下面的例子只是示例性的，不是对本发明范围的限制实例。
例1
VYDYNE容积率为30％的玻璃填充的尼龙66***件，插进有凸缘的第一半个车架纵梁中，用其中的定位孔以机械方法固定。涂上2mm厚的BETABRACE 85076可膨胀环氧树脂泡沫塑料粘合剂的***件，设计成能使直接接触车架纵梁的泡沫塑料量最大。
第二半个车架纵梁焊接到第一半个车架纵梁上，焊接的车架纵梁然后作电泳涂装(e-coating)，电泳涂装液在车架纵梁的所有内腔中自由流动。焊接的车架纵梁再加热到足够的温度，将电泳涂装固化，并用同时固化的树脂将***件与车架纵梁焊封在一起。
BETAFOAM 88100异氰酸酯及BETAFOAM 88124树脂喷入内腔并固化使形成的车架纵梁只在***件与纵梁***部分的范围内得到加固。

Claims (10)

1、一种具有内腔的结构主体的加固方法，包括以下步骤：
a)将带有封头的***件插进结构主体的一部分内腔中，其中，该***件在***位置与结构主体结合，形成增强材料的容置区，该容置区有一入口；
b)使***件与结构主体密封；
c)通过加固区的入口加入足量的未固化增强材料，使其至少部分地填充该容置区；以及
d)使增强材料固化。
2、根据权利要求1所述的方法，其特征在于，该结构主体是车辆的车架纵梁或双开门车身。
3、根据权利要求1或2所述的方法，其特征在于，该未固化的增强材料是可膨胀双组元聚氨酯树脂或可膨胀双组元环氧树脂。
4、根据权利要求3所述的方法，其特征在于，该未固化的增强材料是可膨胀双组元聚氨酯树脂。
5、根据权利要求1-4任一项所述的方法，其特征在于，该***件用热活化的可膨胀环氧树脂粘合剂或热活化的非可膨胀硅酮或丙烯酸粘合剂热密封到结构主体上，或用机械方法密封。
6、根据权利要求1-5任一项所述的方法，其特征在于，该增强材料基本上填充容置区。
7、一种加固的结构主体，包括：a)车辆的车架纵梁或双开门车身具有内腔；b)带有封头的***件位于内腔中并密封，该***件在***位置与结构主体结合，形成至少局部填充增强材料的加固区。
8、根据权利要求7所述的加固的结构主体，其特征在于，该增强材料是可膨胀双组元聚氨酯或固化的可膨胀双组元聚氨酯。
9、根据权利要求7或8所述的加固的结构主体，其特征在于，该结构主体用发泡环氧树脂粘合剂密封。
10.根据权利要求7-9中任一项所述的加固的结构主体，其特征在于，该增强材料基本上填充容置区，而且该***件是填料增强的热塑性塑料，该热塑性塑料包括向未固化增强材料的方向突出的凸形件。
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