CA2410764A1 - Structural reinforcement system having modular segmented characteristics - Google Patents
Structural reinforcement system having modular segmented characteristics Download PDFInfo
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- CA2410764A1 CA2410764A1 CA002410764A CA2410764A CA2410764A1 CA 2410764 A1 CA2410764 A1 CA 2410764A1 CA 002410764 A CA002410764 A CA 002410764A CA 2410764 A CA2410764 A CA 2410764A CA 2410764 A1 CA2410764 A1 CA 2410764A1
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- segments
- bonding material
- modular
- hydroform
- automotive
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- 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
Abstract
A modular segmented structural reinforcement system (10) for use with closed forms or cavities defined with automotive vehicles having a plurality of modular segments (12) designed to be secured within a defined portion of an automotive vehicle applications. An expandable or bonding material (14), suc h as an epoxy-based reinforcing foam or other sound absorption, damping, vibration reduction, or sealing material is disposed on at least a portion of the oute r surface of each of the plurality of segments. Once the system is flexible fitted within the closed form or placed within a selected cavity of an automotive vehicle, the materi al expands and cures during an automobile assembly operation, bonding the reinforcement system to the segments. As a result, the reinforcement system provides enhanced load distribution over the vehicle frame without adding excessive weight and further serves to reduce noise and vibrational characteristics of the automotive vehicle.
Description
Express Mail Label No. EV1~9452 US
Attorney Docket No. 1001-020 STRUCTURAL REINFORCEMENT SYSTEM HAVING MODULAR SEGMENTED
CHARACTERISTICS
FIELD OF THE INVENTION
The present invention relates generally to a structural reinforcement system for use in increasing the stiffness, strength, durability, sealing, and sound absorptionldamping of different portions of a variety of goods and products, such as furniture, commercial, industrial, and household appliances, as well as land transportation vehicles, such as automotive, aerospace, marine, and rail vehicles.
More particularly, the present invention relates to segmented or modularly expandable structurally reinforced closed forms, such as a hydroform structure or hydroform rail, which utilizes a plurality of segmented parts suitable for flexible attachment and capable of providing a unitary structure for reinforcement of a desired area. Once attached as a whole, the segmented portions maintain flexibility for movement and application into specific closed form shapes while the exterior surface of each individual segment or module can be coated with a material selected from a group consisting of a sealing material, or sound damping material, an anti-vibration material, a structurally reinforcing material, or other expandable and foamable material to cross-link, structurally adhere, and reinforce the form when the material becomes chemically active and expands upon heating, self heating, or is otherwise exposed to a heat or energy source.
BACKGROUND OF THE INVENTION
Traditionally, closed form or hydroforming techniques are used to draw and shape metal tubes. Conventional hydroforming techniques often involve two steps:
(1 ) placing the desired bends in the tube and (2) forrning the tube to the desired configuration. The second step of this process usually requires placing a tubular member having an open bore in a mold and pinching off the ends of the tube. A
pressurized liquid is then injected into the open bore, causing the tube to stretch and expand out against the mold.
The manufacturing advantages of the hydroforming process is that it allows formation of relatively long tubular structures having a seamless perimeter.
This process eliminates the cost of welding, machining, or fastening operations often used to shape the part in the desired configuration. As a result, a hydroform or Express Mail Label No. EV1~19452 US
Attorney Docket No. 1001 02 O
closed form structure very often has a high length to diameter ratio. For instance, a hydroform structure may have a length in excess of 15' and a diameter ranging from approximately '/." to more than 12". To this end, a further manufacturing process advantage of a hydroform structure is that it can exceed the length of other tubular members, such as torsion bars or tubular bars, formed using other processes.
AdditionalBy, hydroforming processing creates complex structural shapes that typically include bends and contour changes. Oftern the number of bends and contour changes in a hydroformed bar are greater arid more complex than those found in torsion bars or other tubular structures formed using different techniques.
These shapes often have particular application in land transportation vehicles which require contour changes to reflect vehicle styling and traditional automotive architecture in the form of automotive rails, pillars, and other structural members.
In addition, hydroform structures typically have a constant wall thickness prior to forming, and might develop strength differences at the site of bends or changes in contour, as well as at certain locations along a long tubular section. Thus, it is often desirable to reinforce closed form and hydroform sections to improve their structural stiffness, strength, and durability, particularly in automof~~ive vehicle applications.
Traditional ways of reinforcing tubular structures such as hydroforms and other closed forms include sliding a metal sleeve inside the tube and welding the reinforcing member in place. However, because the hydroform often includes ane or more shapes or bends, or one or more changes in contour and/or diameter, it is often difficult to insert the sleeve into the hydroform at the precise location of the weak portion. Other techniques include reinforcing the hydroform from the outside by welding the sleeve onto the outside of the hydroforrn. However, hydroforms are often used in applications having very close toleran~;,es, resulting in little or no clearance for an externally placed reinforcing member. Accordingly, exterior reinforcements are often not as effective as interior reinforcements.
Additionally, in many operations the weight of the tubular member is critical and must be kept low as possible. Thus, the use of an external sleeve adds unwanted weight to the tubular assembly. Still further, the welding operation tends to be labor intensive during the manufacturing process, time consuming and inexact, increasing the cost of forming the hydroform member and producing parts that have questionable reliability. Finally, these additional manufacturing steps and operations are often cumbersome and difficult to integrate into a final vehicle manufacturing Express Mail Label No. EV1~g452 US
Attorney Docket No. 1001-02 O
process in that additional tooling would need to be developed by the manufacturer and assembly plant resources, labor, maintenance, and space would need to be dedicated and expensed by the vehicle manufacturer.
Accordingly, there is a need in industry and manufacturing operations for S system, device, and method for reinforcing the weak areas of closed forms and other hydroform tubes, such as a hydroform rail, without significantly increasing the weight and manufacturing complexity. In particular, there is a need for reinforcing a closed form or hydroform, which utilizes a plurality of segments car portions to achieve integrated reinforcement within the closed form since the contour or shape of typical tubes do not allow for placement of single piece reinforcement members. In this regard, the present invention addresses and overcomes the shortcomings found in the prior art by providing a multi-segment reinforcement system having at least two segments or portions capable of being modularly attached or otherwise engaged in segments within a hydroform that may then be faxed in location through the use of a third segment or portion which serves as a locking, positioning, and retaining member of the reinforcement system within the hydroform or other closed form.
However, the plurality of modularly attached segments could also be locked, positioned, and retained within a hydroform through the use of retention means, such as a string, wire, or chain looped through each of the segments which provides enough tension to retain each of the segments in a desired position while the entire system (i.e. the segments with an amount of bonding material disposed along at least a portion of each of the segments) is exposed and cured by the heat typically encountered in an automotive painting operation. Structural reinforcement of the hydroform is achieved through activation by heat of the bonding material disposed along at least a portion of an outer or exterior surface of the plurality of segments or portions, such a material would typically expand when exposed to heat or other energy source and in doing so structurally adhere the segments or portions to each other and the hydroform. Further, it is contemplated that the system would have greater flexibility to a range of applications by allowing each segment or portion of the plurality of segments to also have the capability of receiving a suitable amount of sealing material, sound absorption material, andlor ~an expandable material, or a combination thereof.
Attorney Docket No. 1001-020 STRUCTURAL REINFORCEMENT SYSTEM HAVING MODULAR SEGMENTED
CHARACTERISTICS
FIELD OF THE INVENTION
The present invention relates generally to a structural reinforcement system for use in increasing the stiffness, strength, durability, sealing, and sound absorptionldamping of different portions of a variety of goods and products, such as furniture, commercial, industrial, and household appliances, as well as land transportation vehicles, such as automotive, aerospace, marine, and rail vehicles.
More particularly, the present invention relates to segmented or modularly expandable structurally reinforced closed forms, such as a hydroform structure or hydroform rail, which utilizes a plurality of segmented parts suitable for flexible attachment and capable of providing a unitary structure for reinforcement of a desired area. Once attached as a whole, the segmented portions maintain flexibility for movement and application into specific closed form shapes while the exterior surface of each individual segment or module can be coated with a material selected from a group consisting of a sealing material, or sound damping material, an anti-vibration material, a structurally reinforcing material, or other expandable and foamable material to cross-link, structurally adhere, and reinforce the form when the material becomes chemically active and expands upon heating, self heating, or is otherwise exposed to a heat or energy source.
BACKGROUND OF THE INVENTION
Traditionally, closed form or hydroforming techniques are used to draw and shape metal tubes. Conventional hydroforming techniques often involve two steps:
(1 ) placing the desired bends in the tube and (2) forrning the tube to the desired configuration. The second step of this process usually requires placing a tubular member having an open bore in a mold and pinching off the ends of the tube. A
pressurized liquid is then injected into the open bore, causing the tube to stretch and expand out against the mold.
The manufacturing advantages of the hydroforming process is that it allows formation of relatively long tubular structures having a seamless perimeter.
This process eliminates the cost of welding, machining, or fastening operations often used to shape the part in the desired configuration. As a result, a hydroform or Express Mail Label No. EV1~19452 US
Attorney Docket No. 1001 02 O
closed form structure very often has a high length to diameter ratio. For instance, a hydroform structure may have a length in excess of 15' and a diameter ranging from approximately '/." to more than 12". To this end, a further manufacturing process advantage of a hydroform structure is that it can exceed the length of other tubular members, such as torsion bars or tubular bars, formed using other processes.
AdditionalBy, hydroforming processing creates complex structural shapes that typically include bends and contour changes. Oftern the number of bends and contour changes in a hydroformed bar are greater arid more complex than those found in torsion bars or other tubular structures formed using different techniques.
These shapes often have particular application in land transportation vehicles which require contour changes to reflect vehicle styling and traditional automotive architecture in the form of automotive rails, pillars, and other structural members.
In addition, hydroform structures typically have a constant wall thickness prior to forming, and might develop strength differences at the site of bends or changes in contour, as well as at certain locations along a long tubular section. Thus, it is often desirable to reinforce closed form and hydroform sections to improve their structural stiffness, strength, and durability, particularly in automof~~ive vehicle applications.
Traditional ways of reinforcing tubular structures such as hydroforms and other closed forms include sliding a metal sleeve inside the tube and welding the reinforcing member in place. However, because the hydroform often includes ane or more shapes or bends, or one or more changes in contour and/or diameter, it is often difficult to insert the sleeve into the hydroform at the precise location of the weak portion. Other techniques include reinforcing the hydroform from the outside by welding the sleeve onto the outside of the hydroforrn. However, hydroforms are often used in applications having very close toleran~;,es, resulting in little or no clearance for an externally placed reinforcing member. Accordingly, exterior reinforcements are often not as effective as interior reinforcements.
Additionally, in many operations the weight of the tubular member is critical and must be kept low as possible. Thus, the use of an external sleeve adds unwanted weight to the tubular assembly. Still further, the welding operation tends to be labor intensive during the manufacturing process, time consuming and inexact, increasing the cost of forming the hydroform member and producing parts that have questionable reliability. Finally, these additional manufacturing steps and operations are often cumbersome and difficult to integrate into a final vehicle manufacturing Express Mail Label No. EV1~g452 US
Attorney Docket No. 1001-02 O
process in that additional tooling would need to be developed by the manufacturer and assembly plant resources, labor, maintenance, and space would need to be dedicated and expensed by the vehicle manufacturer.
Accordingly, there is a need in industry and manufacturing operations for S system, device, and method for reinforcing the weak areas of closed forms and other hydroform tubes, such as a hydroform rail, without significantly increasing the weight and manufacturing complexity. In particular, there is a need for reinforcing a closed form or hydroform, which utilizes a plurality of segments car portions to achieve integrated reinforcement within the closed form since the contour or shape of typical tubes do not allow for placement of single piece reinforcement members. In this regard, the present invention addresses and overcomes the shortcomings found in the prior art by providing a multi-segment reinforcement system having at least two segments or portions capable of being modularly attached or otherwise engaged in segments within a hydroform that may then be faxed in location through the use of a third segment or portion which serves as a locking, positioning, and retaining member of the reinforcement system within the hydroform or other closed form.
However, the plurality of modularly attached segments could also be locked, positioned, and retained within a hydroform through the use of retention means, such as a string, wire, or chain looped through each of the segments which provides enough tension to retain each of the segments in a desired position while the entire system (i.e. the segments with an amount of bonding material disposed along at least a portion of each of the segments) is exposed and cured by the heat typically encountered in an automotive painting operation. Structural reinforcement of the hydroform is achieved through activation by heat of the bonding material disposed along at least a portion of an outer or exterior surface of the plurality of segments or portions, such a material would typically expand when exposed to heat or other energy source and in doing so structurally adhere the segments or portions to each other and the hydroform. Further, it is contemplated that the system would have greater flexibility to a range of applications by allowing each segment or portion of the plurality of segments to also have the capability of receiving a suitable amount of sealing material, sound absorption material, andlor ~an expandable material, or a combination thereof.
Express Mail Label No. EV~i9452 US
Attorney Docket No. 1001-028W0 SUMMARY OF THE INVENTION
The present invention relates to methods and systems 'for reinforcing a closed form or hydroform member. In one embodiment, the ;system includes a plurality of segments having a bonding material disposed over at least a portion of the exterior or outer surface of the segments which may or may not be expandable upon exposure to heat or other energy source. The selected bonding material extends along at least a portion of the exterior surface of at least one segment which are then configured for placement within a portion of a automotive vehicle to be reinforced.
In a particular preferred embodiment, the bonding material consists of an expandable material which is generally and preferably ~a heat-activated epoxy-based resin having foamable characteristics upon activation through the use of heat typically encountered in an e-coat process, paint oven, or other automotive painting operation. As the material is heated or otherwise exposed to an energy source in the manufacturing environment, it expands, cross-links, and structurally adheres to iS adjacent surfaces. Preferred structural foam or expandable materials are commercially available from LB~L Products, Inc. of Romeo, Michigan under the designation L5204, L5206, L5207, L5208, or L5209. Generally speaking, these automotive vehicle applications may utilize technology and processes such as those disclosed in U.S. Patent Nos. 4,922,596, 4,978,562, 5,124,186, and 5,884,960 and commonly owned, co-.pending U.S. Application Serial Nos. 091502,686 filed February 11, 2000, 09/524,961 filed March 14, 2000, and particularly, 09/459,756 filed December 10, 1999, all of which are expressly incorporated by reference.
The system generally employs two or more segments or portions defined adapted for stiffening the structure to be reinforced and helping to redirect applied loads. In use, the segments are inserted into a closed form, such as a hydroformed tube, or simply placed or retained in a cavity by retention means defined within portions of an automotive vehicle such as a pillar, rail, rocker, door assembly, or other frame member, with the heat activated bonding material serving as the load transferring and potentially energy absorbing medium. In a particularly preferred embodiment, at least two of 'the segments are composed of a polymeric material, such as nylon, an injection molded nylon carrier, an injection molded polymer, graphite, carbon, or a molded metal (such as aluminum, magnesium, and titanium, an alloy derived from the metals or a metallic foam derived from these metals or other metal foam) and is at least partially coated with a bonding material on at least Express Mail Label No..EV19452 US , Attorney Docket No. 1001-028w0 one of its sides, and in some instances on four or more sides. A preferred bonding material is an epoxy-based resin, such as L5204, L5206, L5207, L520~ or L5209 structural foam commercially available from L & L. Products, Inc. of Romeo, Michigan. However, the present invention may further comprise retention means in an alternative form consisting of a third member, segment, or portion which serves to lock and position the at least first two segments in place. This retention means could also utilize an adhesive material disposed along an outer surface of each of the members, segments, or portions. Still further, the retention means, which serves to lock, position, and retain the plurality of members or sE;gments within the hydroform could also comprise locking means, such as a string, wire, or chain looped through each of the segments which provides enough tension to retain the plurality of segments in a desired position while the bonding material is activated in the e-coat or painting operation. Once the bonding material is activated and cured, it is contemplated that the bonding material will structurally secure and retain the plurality of segments in the desired position within the portion of the vehicle to be reinforced.
In addition, it is contemplated that the- plurality of segments could comprise a nylon or other polymeric material as set forth in comrnoniy owned U.S. Patent No.
6,103,341, expressly incorporated by reference herein. Still further, the segments adapted for stiffening the structure to be reinforced could comprise a stamped and formed cold-rolled steel, a stamped and formed high strength low alloy steel, a stamped and formed transformation induced plasticity (TRIP) steel, a roll formed cold rolled steel, a roll formed high strength low alloy steel, or a roll formed transformation induced plasticity (TRIP) steel, as well as an elastomer, polyethylene, ethylene-vinyl acetate copolymer, plasticized polyvinyl chloride film;, polyamide, polysulfone, or various olfenic copolymer and terpolymer materials. Although the bonding material of the present invention does not need to be either heat-activatable or expandable, a preferred material used in the present invention is an expandable structural material.
The choice of the material selected as the bonding material will be dictated by performance requirements and economics of a specific application.
Additional bonding materials that could be utilised in the present invention include other materials which are suitable as acoustic media (i.e. sound absorbing, sound damping, or impacting NVH characteristics) and which may be' heat activated which generally activate and expand to fill a desired cavity or occupy a desired space or function when exposed to temperatures typically encountered in automotive e-Facpress Mail Label Na. EV17lf9452 U8 Attorney Docket No. 1001-028W~
coat curing ovens and other paint operations ovens. Though other heat-activated materials are possible, a preferred heat activated material is an expandable or flowable polymeric formulation, and preferably one theft can activate to foam, flow, adhere, or otherwise change states when exposed to the heating operation of a typical automotive assembly painting operation. For example, without limitation, in one embodiment, the polymeric foam is based on ethylene copolymer or terpolymer that may possess an alpha-olefin. As a copolymer car terpolymer,, the polymer is composed of two or three different monomers, i.e., small molecules with high chemical reactivity that are capable of linking up with sirnilar molecules.
Examples of particularly preferred polymers include ethylene vinyl acetate, EP~M, or a mixture thereof. Without limitation, other examples of preferrE:d foam formulation that are commercially available include polymer-based material commercially available from L&L Products, lnc. of Romeo, Michigan, under the designations as L-2105, L-2100, L-7005 or L-2018, L-7101, L-7102, L-2411, L-2420, L-4141, etc. and may comprise either open or closed cell polymeric base material.
Further, it is contemplated that the plurality of segments or portions of the present invention could employ a suitable amount of sealing, sound dampening, structural reinforcement, or acoustic material in combination upon different surfaces of the plurality of segments within the selected area to be reinforced to achieve specific points of reinforcement, sealing, andlor sound damping depending upon the individual needs or desirability of the specific application. When activated through the application of heat, it is contemplated that a segment specific material will achieve not only structural reinforcement, but may also assist in the reduction of vibration and noise in the overall automotive body depending upon the characteristics of the . chosen bonding material. In this regard; the now reinfonxd area, closed form, or hydroform will have increased stiffness in the cross-members, which will shift the natural frequency, measured in hertz that resonates through the automotive chassis and will reduce acoustic transmission and the ability to block or absorb noise through the use of the conjunctive acoustic, sealing, or sound damping product. By increasing the stiffness and rigidity of the cross-members, the noise and frequency of the overall engine ride vibration that occurs from the operation of the vehicle can be reduced since a shift in frequency of noise and vibration will allow resonance through the chassis. Although the use of such Sealing, damping, and vibration reducing materials or media can be utilized instead of, or in conjunction Express Mail Label No. EV1 9452 US
Attorney Docket No. 1001-028W0 with, the structural expandable material on the individual segments of the present invention, the preferred embodiment of the structural reinforcement system of the present invention utilizes a bonding material consisting of a structurally reinforcing expandable material. Use of acoustic materials in conjunction with structural may provide additional structural improvement but primarily would be incorporated to improve NVH characteristics.
It is also contemplated that the material of the present invention could be delivered and placed into contact with the segments through a variety of delivery systems which include, but are not limited to, a mechanical snap fit assembly, extrusion techniques commonly known in the art as well as a mint-applicator technique as in accordance with the teachings of commonly owned U.S. Patent No.
5,358,397 ("Apparatus For Extruding Flowable Materials"), hereby expressly incorporated by reference. In this non-limiting embodiment, the material is at least partially coated with heat-activated material that could be structural, sealing, dampening, or acoustic in nature. This preferably heat activated material can be snap-fit onto the chosen surface or substrate; placed into beads or pei.iets for placement along the chosen substrate or member by means of extrusion, placed along the substrate through the use of baffle technology, die-cut according to teachings that are well known in the art, utilize pumpable application systems which could include the use of a baffle and bladder system, as well as sprayable applications.
In another embodiment, the plurality of segments are composed of an injection molded nylon and provided with a suitable amount of bonding material or load transfer medium molded onto its sides in at least one location defining a portion wherein each portion is smaller in diameter than a corresponding insertable opening in the form or tube to enable placement within a cavity defined within an automotive vehicle, such as portions of a hydroform tube, hydroform rail, or other area or substrate found in an automotive vehicle which could benefit from the structural reinforcement characteristics found in the present invention. In this embodiment a plurality of modularly attachable segments or portions are utilized to provide an integrated member, having flexible characteristics relative to one another similar to the movements of an accordian, for installation within a hydrofromed rail or other area of a vehicle that would benefit from structural reinforcement . For example, a first segment or portion corresponds to, and is insertably attached to an opening Express Mail Labe! No. EV194S2 US
Attorney Docket No. 1001-028W0 located within the hydroform tube or hydrofrom rail section. A second segment or portion is modularly attachable or slideably engaged and affixed to a surface of the first segment or portion. A third segment or portion, and a plurality of portions thereafter, is then modularly attached or slideably engaged and affixed to a surface of the preceding plurality of segments. It is contemplated that the modularly attached or slideably engaged plurality of segments will stilt provide a certain degree of freedom or flexibility whereby the plurality of segments can flex and be shaped to fit within the contours or geometric requirements of the area to be structurally reinforced. A fixed locking member or retention means, such as a heal and toe feature, is then utilized to place or fix the plurality of segments or portions together within the area to be reinforced thereby retaining the segments. Further, the locking member could comprise tension means, such as a string, wire, chain, or cable retaining the plurality of segments with the bonding material on the exterior surface of the segments in a desired position while the system undergoes baking in an automotive painting operation. The bonding material is activated to accomplish expansion through the application of heat typically encountered in an automotive e-coat oven or other painting operation oven in the space defined between the plurality of segments or portions and the walls of the cavity selected for reinforcement. The resulting structure includes the wall structure of the hydroform tube or cavity joined to the plurality of segments with the aid of the now activated bonding material.
It is contemplated that each individual segment or portion could be configured for application of a bonding material, expandable material, or sealing material applied in a variety of patterns, shapes, and thicknesses to accommodate the particular size, shape, and dimensions of the cavity corresponding to the chosen form or vehicle application..
Bf~IEF DESCRIPTION OF THE DRN1NIINC°aS
The features and inventive aspects of the present: invention will become more apparent upon reading the following detailed description, .claims and drawings, of which the. following is a brief description:
F1G. 1 is a perspective view of a modular segmented structural reinforcement system in accordance with the teachings of the present invention.
Attorney Docket No. 1001-028W0 SUMMARY OF THE INVENTION
The present invention relates to methods and systems 'for reinforcing a closed form or hydroform member. In one embodiment, the ;system includes a plurality of segments having a bonding material disposed over at least a portion of the exterior or outer surface of the segments which may or may not be expandable upon exposure to heat or other energy source. The selected bonding material extends along at least a portion of the exterior surface of at least one segment which are then configured for placement within a portion of a automotive vehicle to be reinforced.
In a particular preferred embodiment, the bonding material consists of an expandable material which is generally and preferably ~a heat-activated epoxy-based resin having foamable characteristics upon activation through the use of heat typically encountered in an e-coat process, paint oven, or other automotive painting operation. As the material is heated or otherwise exposed to an energy source in the manufacturing environment, it expands, cross-links, and structurally adheres to iS adjacent surfaces. Preferred structural foam or expandable materials are commercially available from LB~L Products, Inc. of Romeo, Michigan under the designation L5204, L5206, L5207, L5208, or L5209. Generally speaking, these automotive vehicle applications may utilize technology and processes such as those disclosed in U.S. Patent Nos. 4,922,596, 4,978,562, 5,124,186, and 5,884,960 and commonly owned, co-.pending U.S. Application Serial Nos. 091502,686 filed February 11, 2000, 09/524,961 filed March 14, 2000, and particularly, 09/459,756 filed December 10, 1999, all of which are expressly incorporated by reference.
The system generally employs two or more segments or portions defined adapted for stiffening the structure to be reinforced and helping to redirect applied loads. In use, the segments are inserted into a closed form, such as a hydroformed tube, or simply placed or retained in a cavity by retention means defined within portions of an automotive vehicle such as a pillar, rail, rocker, door assembly, or other frame member, with the heat activated bonding material serving as the load transferring and potentially energy absorbing medium. In a particularly preferred embodiment, at least two of 'the segments are composed of a polymeric material, such as nylon, an injection molded nylon carrier, an injection molded polymer, graphite, carbon, or a molded metal (such as aluminum, magnesium, and titanium, an alloy derived from the metals or a metallic foam derived from these metals or other metal foam) and is at least partially coated with a bonding material on at least Express Mail Label No..EV19452 US , Attorney Docket No. 1001-028w0 one of its sides, and in some instances on four or more sides. A preferred bonding material is an epoxy-based resin, such as L5204, L5206, L5207, L520~ or L5209 structural foam commercially available from L & L. Products, Inc. of Romeo, Michigan. However, the present invention may further comprise retention means in an alternative form consisting of a third member, segment, or portion which serves to lock and position the at least first two segments in place. This retention means could also utilize an adhesive material disposed along an outer surface of each of the members, segments, or portions. Still further, the retention means, which serves to lock, position, and retain the plurality of members or sE;gments within the hydroform could also comprise locking means, such as a string, wire, or chain looped through each of the segments which provides enough tension to retain the plurality of segments in a desired position while the bonding material is activated in the e-coat or painting operation. Once the bonding material is activated and cured, it is contemplated that the bonding material will structurally secure and retain the plurality of segments in the desired position within the portion of the vehicle to be reinforced.
In addition, it is contemplated that the- plurality of segments could comprise a nylon or other polymeric material as set forth in comrnoniy owned U.S. Patent No.
6,103,341, expressly incorporated by reference herein. Still further, the segments adapted for stiffening the structure to be reinforced could comprise a stamped and formed cold-rolled steel, a stamped and formed high strength low alloy steel, a stamped and formed transformation induced plasticity (TRIP) steel, a roll formed cold rolled steel, a roll formed high strength low alloy steel, or a roll formed transformation induced plasticity (TRIP) steel, as well as an elastomer, polyethylene, ethylene-vinyl acetate copolymer, plasticized polyvinyl chloride film;, polyamide, polysulfone, or various olfenic copolymer and terpolymer materials. Although the bonding material of the present invention does not need to be either heat-activatable or expandable, a preferred material used in the present invention is an expandable structural material.
The choice of the material selected as the bonding material will be dictated by performance requirements and economics of a specific application.
Additional bonding materials that could be utilised in the present invention include other materials which are suitable as acoustic media (i.e. sound absorbing, sound damping, or impacting NVH characteristics) and which may be' heat activated which generally activate and expand to fill a desired cavity or occupy a desired space or function when exposed to temperatures typically encountered in automotive e-Facpress Mail Label Na. EV17lf9452 U8 Attorney Docket No. 1001-028W~
coat curing ovens and other paint operations ovens. Though other heat-activated materials are possible, a preferred heat activated material is an expandable or flowable polymeric formulation, and preferably one theft can activate to foam, flow, adhere, or otherwise change states when exposed to the heating operation of a typical automotive assembly painting operation. For example, without limitation, in one embodiment, the polymeric foam is based on ethylene copolymer or terpolymer that may possess an alpha-olefin. As a copolymer car terpolymer,, the polymer is composed of two or three different monomers, i.e., small molecules with high chemical reactivity that are capable of linking up with sirnilar molecules.
Examples of particularly preferred polymers include ethylene vinyl acetate, EP~M, or a mixture thereof. Without limitation, other examples of preferrE:d foam formulation that are commercially available include polymer-based material commercially available from L&L Products, lnc. of Romeo, Michigan, under the designations as L-2105, L-2100, L-7005 or L-2018, L-7101, L-7102, L-2411, L-2420, L-4141, etc. and may comprise either open or closed cell polymeric base material.
Further, it is contemplated that the plurality of segments or portions of the present invention could employ a suitable amount of sealing, sound dampening, structural reinforcement, or acoustic material in combination upon different surfaces of the plurality of segments within the selected area to be reinforced to achieve specific points of reinforcement, sealing, andlor sound damping depending upon the individual needs or desirability of the specific application. When activated through the application of heat, it is contemplated that a segment specific material will achieve not only structural reinforcement, but may also assist in the reduction of vibration and noise in the overall automotive body depending upon the characteristics of the . chosen bonding material. In this regard; the now reinfonxd area, closed form, or hydroform will have increased stiffness in the cross-members, which will shift the natural frequency, measured in hertz that resonates through the automotive chassis and will reduce acoustic transmission and the ability to block or absorb noise through the use of the conjunctive acoustic, sealing, or sound damping product. By increasing the stiffness and rigidity of the cross-members, the noise and frequency of the overall engine ride vibration that occurs from the operation of the vehicle can be reduced since a shift in frequency of noise and vibration will allow resonance through the chassis. Although the use of such Sealing, damping, and vibration reducing materials or media can be utilized instead of, or in conjunction Express Mail Label No. EV1 9452 US
Attorney Docket No. 1001-028W0 with, the structural expandable material on the individual segments of the present invention, the preferred embodiment of the structural reinforcement system of the present invention utilizes a bonding material consisting of a structurally reinforcing expandable material. Use of acoustic materials in conjunction with structural may provide additional structural improvement but primarily would be incorporated to improve NVH characteristics.
It is also contemplated that the material of the present invention could be delivered and placed into contact with the segments through a variety of delivery systems which include, but are not limited to, a mechanical snap fit assembly, extrusion techniques commonly known in the art as well as a mint-applicator technique as in accordance with the teachings of commonly owned U.S. Patent No.
5,358,397 ("Apparatus For Extruding Flowable Materials"), hereby expressly incorporated by reference. In this non-limiting embodiment, the material is at least partially coated with heat-activated material that could be structural, sealing, dampening, or acoustic in nature. This preferably heat activated material can be snap-fit onto the chosen surface or substrate; placed into beads or pei.iets for placement along the chosen substrate or member by means of extrusion, placed along the substrate through the use of baffle technology, die-cut according to teachings that are well known in the art, utilize pumpable application systems which could include the use of a baffle and bladder system, as well as sprayable applications.
In another embodiment, the plurality of segments are composed of an injection molded nylon and provided with a suitable amount of bonding material or load transfer medium molded onto its sides in at least one location defining a portion wherein each portion is smaller in diameter than a corresponding insertable opening in the form or tube to enable placement within a cavity defined within an automotive vehicle, such as portions of a hydroform tube, hydroform rail, or other area or substrate found in an automotive vehicle which could benefit from the structural reinforcement characteristics found in the present invention. In this embodiment a plurality of modularly attachable segments or portions are utilized to provide an integrated member, having flexible characteristics relative to one another similar to the movements of an accordian, for installation within a hydrofromed rail or other area of a vehicle that would benefit from structural reinforcement . For example, a first segment or portion corresponds to, and is insertably attached to an opening Express Mail Labe! No. EV194S2 US
Attorney Docket No. 1001-028W0 located within the hydroform tube or hydrofrom rail section. A second segment or portion is modularly attachable or slideably engaged and affixed to a surface of the first segment or portion. A third segment or portion, and a plurality of portions thereafter, is then modularly attached or slideably engaged and affixed to a surface of the preceding plurality of segments. It is contemplated that the modularly attached or slideably engaged plurality of segments will stilt provide a certain degree of freedom or flexibility whereby the plurality of segments can flex and be shaped to fit within the contours or geometric requirements of the area to be structurally reinforced. A fixed locking member or retention means, such as a heal and toe feature, is then utilized to place or fix the plurality of segments or portions together within the area to be reinforced thereby retaining the segments. Further, the locking member could comprise tension means, such as a string, wire, chain, or cable retaining the plurality of segments with the bonding material on the exterior surface of the segments in a desired position while the system undergoes baking in an automotive painting operation. The bonding material is activated to accomplish expansion through the application of heat typically encountered in an automotive e-coat oven or other painting operation oven in the space defined between the plurality of segments or portions and the walls of the cavity selected for reinforcement. The resulting structure includes the wall structure of the hydroform tube or cavity joined to the plurality of segments with the aid of the now activated bonding material.
It is contemplated that each individual segment or portion could be configured for application of a bonding material, expandable material, or sealing material applied in a variety of patterns, shapes, and thicknesses to accommodate the particular size, shape, and dimensions of the cavity corresponding to the chosen form or vehicle application..
Bf~IEF DESCRIPTION OF THE DRN1NIINC°aS
The features and inventive aspects of the present: invention will become more apparent upon reading the following detailed description, .claims and drawings, of which the. following is a brief description:
F1G. 1 is a perspective view of a modular segmented structural reinforcement system in accordance with the teachings of the present invention.
Express Mail Label No. EV19452 US
Attorney Docket No. 1001-028w0 F1G. 2 is an exploded section view of a portion of a hydroform described in FIG. 1, showing the position of the plurality of modular segments and the expandable material in the uncured state.
FIG. 3 is a cutaway sectional view of a modular segmented structural reinforcement system in accordance with the teachings of the present invention placed within a hydroform in accordance.with the teachings of the present invention prior to activation of the expandable material.
FIG: 4 is a cutaway sectional view of a modular segmented structural . reinforcement system in accordance with the teachings of the present invention placed within a hydroform in accordance with the teachings of the present invention after activation of the expandable material.
FIG. 5 is a cutaway sectional view of an alternative embodiment of the modular segmented structural reinforcement system placed within automotive vehicle pillar without the use of a hydroform in accordance with the teachings of the present invention F1G. 6 is a partial perspective view of an alternative embodiment of the modular segmented structural reinforcement system in accordance with the teachings of the present invention showing a plurality of modular segments held together by attachment means which permit the flexing of at least one modular segment relative to one another for placement in either a hydroform or directly to portions of an automotive vehicle.
FIG. 7 is a perspective view of a an alterriative embodiment of the modular segmented structural reinforcement system in accordance with the teachings of the present invention showing a plurality of modular segments held together by attachment means comprising a traditional bail and socket assembly which permits the flexing of at least one modular segment relative to one another for placement in either a hydroform or directly to portions of an automotive vehicle.
F1G. 8 is a perspective view of a an alternativeembodiment of the modular segmented structural reinforcement system in accordance with the teachings of the present invention showing a plurality of modular segments held together by attachment means comprising a hitch snap assembly which permits the flexing of at least one modular segment relative to one another for placement in either a hydroform or directly to portions of an automotive vehicle.
Attorney Docket No. 1001-028w0 F1G. 2 is an exploded section view of a portion of a hydroform described in FIG. 1, showing the position of the plurality of modular segments and the expandable material in the uncured state.
FIG. 3 is a cutaway sectional view of a modular segmented structural reinforcement system in accordance with the teachings of the present invention placed within a hydroform in accordance.with the teachings of the present invention prior to activation of the expandable material.
FIG: 4 is a cutaway sectional view of a modular segmented structural . reinforcement system in accordance with the teachings of the present invention placed within a hydroform in accordance with the teachings of the present invention after activation of the expandable material.
FIG. 5 is a cutaway sectional view of an alternative embodiment of the modular segmented structural reinforcement system placed within automotive vehicle pillar without the use of a hydroform in accordance with the teachings of the present invention F1G. 6 is a partial perspective view of an alternative embodiment of the modular segmented structural reinforcement system in accordance with the teachings of the present invention showing a plurality of modular segments held together by attachment means which permit the flexing of at least one modular segment relative to one another for placement in either a hydroform or directly to portions of an automotive vehicle.
FIG. 7 is a perspective view of a an alterriative embodiment of the modular segmented structural reinforcement system in accordance with the teachings of the present invention showing a plurality of modular segments held together by attachment means comprising a traditional bail and socket assembly which permits the flexing of at least one modular segment relative to one another for placement in either a hydroform or directly to portions of an automotive vehicle.
F1G. 8 is a perspective view of a an alternativeembodiment of the modular segmented structural reinforcement system in accordance with the teachings of the present invention showing a plurality of modular segments held together by attachment means comprising a hitch snap assembly which permits the flexing of at least one modular segment relative to one another for placement in either a hydroform or directly to portions of an automotive vehicle.
Express Mait Label No. EV1 9452 US
Attorney Docket No. 1001-028W~
FIG. 9 is a perspective view of a an alternativE; embodiment of the modular segmented structural reinforcement system in accordance with the teachings of the present invention showing a plurality of modular segments held together by attachment means comprising a chain assembly which permits the flexing of at Least one modular segment relative to one another for placement in either a hydroform or directly to portions of an automotive vehicle.
DESCRIPTION OF 1'HE PREFERRED EMBODIMENT
FIG. 1 shows a modular segmented reinforcement system 10 formed in accordance with the teachings of the present inventic>n. The modular segmented reinforcement system 10 may impart increased strength, stiffness, sealing, sound absorption, or durability to a structural member or otl'7er portion of an automotive vehicle, and, thus, may be used in a variety of applications for different products.
For instance, the modular segmented reinforcement system 10 may be used as part of the frame or rail systeri~ for automobiles and building structures. Other applications of the system 10 include furniture stems, appliances, and aerospace, marine, rail, and automotive vehicles.
In a preferred embodiment, as in Fig. 2, the present invention comprises at~
least two segments 12 composed of an injection molded polymer. The.segments 12 are provided with a suitable amount of a bonding material 1~4 molded or disposed along the exterior surface or sides of the segments 12 thereby defining a plurality of segmented portions 16 wherein each portion 16 is smaller in diameter than a corresponding insertable opening in the form or tube 18. The segments 12 are modular and are capable of being shaped and sized to fit a variety of closed form applications, such as a hydroform rail. ~iowever, it is contemplated that the segments 12 can be of any geometric size, shape, and dimension corresponding to the selected area to be reinforced or damped. The plurality of segments 12 are suitable for placement within a cavity defined within an automotive vehicle, such as portions of a hydrofrom frame rail, tube section, pillar, rocker, gate, or other area or substrate found in an automotive vehicle which could benefit from the structural reinforcement characteristics found' in the present invention. In this.
embodiment, a first modular segment or portion 20 corresponds to, and is insertably attached to an opening located within a hydroform rail section or other area to be-structurally Express Mail Label No. EV19452 l!S
Attorney Docket IVo. 1001-028w0 reinforced, such as a cavity found in an automotive vehicle. A second modular segment or portion 22 is slideably engaged and affixed to a portion of the first modular segment 20. The present invention provides for a plurality of successive modular segments or portions that can be slideably engaged and affxed to one another thereby forming a unitary reinforcement system for placement within the hydroform rail or tube 18 or other cavity selected for structural reinforcement. It is contemplated that the plurality of modular segments or portions is both flexible and shapeable to the contour and shape of the desired closed form or hydroform, as well as the geometric configuration of other areas selected for reinforcement. In other words, it is contemplated that each of the plurality of segments 12 ace fVexible relative to each other so that the system 10 can be substantially formed to follow the contours of the tube 18 or other chosen portion of an automotive vehicle with or without the use of a tube 18.. Accordingly, once a first modular segment or portion 20, consisting of a segment with the bonding material 14~ placed along the segment, is positioned and slideably engaged with a second modular segment or portion 22, the now unitary first 20 and second 22 modular segments or portions provide a degree of movement or flexibility . relative - to one another thereby providing reinforcement along the contours and specific shape of the hydroform which cannot be achieved through injection molding, sheet metal applications, or other processes disclosed in the prior art. A locking or retaining member 24, which can comprise an additional segment, portion, or retention means or assembly, is then utilized to fixedly bridge the at least first 20 and second 22 segments or portions together.
Although a ball and socket feature well known in the art is shown as the locking member or means in FIG. 7, it is contemplated that locking member 24 could be shaped and configured to position and retain any number of a plurality of segments or portions and that the present invention simply discloses at least two segments or portions for illustrative purposes only and should not be limited to the number of modular segments and corresponding flexible shapes that may be desirable in a variety of applications. In addition, the locking member or retention means 24 could comprise a traditional string, wire, or cable looped or tied through each of the plurality of modular segments thereby retaining the modular segments in a desired position or simply to achieve retention of the segments 12 or portions 16 in a flexible or accordion-like state whereby each segment 12 or portion 16 could move relative to each other for placement within a defined shape or cavity of an automotive vehicle Express Mail Label No. EV19452 US
Attorney Docket No. 1001-028Wn which .does not utilize a tube or form, as shown in FIGS. 8-9. In this regard, the bonding material 14 disposed along the exterior surface or sides of the segments 12, once activated to accomplish expansion through the application of heat typically encountered in an automotive e-coat oven or other heating operation, positions and locks the plurality of segments in space along the walls of the tube or portion of the automotive vehicle defining the cavity. The resulting structure may include the wall structure joined to the plurality of segments with the aid of the activated material 14.
It is contemplated that the material 14 could be applied to the exterior surface or sides of each of the plurality of modular segments in a variety of patterns, shapes, and thicknesses to accommodate the particular size, shape, and dimensions of the cavity corresponding to the chosen form or vehicle application. In addition, each of the plurality of segments could provide a versatile function depending upon the chosen hydroform application. For example, the bonding material 14 could comprise a sealing material, a sound absorption material, a damping material, or a structural reinforcement material. These different variations of the bonding vmaterial 14~ could be placed alone or in combination on different segments or different portions of segments to achieve a desired localized result along tl~e tube 18,. such as localized structural reinforcement, localized sealing, andlor localized sound damping.
The material 14 is activated to accomplish expansion through the application of heat typically encountered in an automotive e-coat oven or other heating operation in the space defined between the plurality of segments and the walls of the hydroform tube or the portion of the.vehicle defining the cavity. The resulting structure includes the wall structure of the hydroform tube or cavity joined to the plurality of segments with the aid of the chosen material 14.
In one embodiment, at least two of the modular segments and, as shown, the first 20 and second 22 segments are nested together within the hydroform tube with each having an application of the bonding material 14. A locking member 24, which is suitable for receiving an amount of bonding material 14 along one or more of its exterior or outer surfaces, is then either placed into contact with the first 20 and second 22 segments or insertably engaged through the hydroform tube 18 to serve as a locking and positioning member of the reinforcement system. Structural reinforcement of the hydroform tubs 18 is achieved through activation by 'heat or some other activation stimulus or source of energy applied to the material 14 disposed along at feast the first 20 and second 22 modular segments wherein the Express Mail Label No. EV1 8452 US
Attorney Docket No. 1001-028W~
material 14 may expand and will structurally adhere the at least two modular segments 20 and 22, and the locking member. 24 to each other and the hydroform tube 18.
In a preferred embodiment, it is contemplated that the bonding material 14 comprises a structural foam, which is more preferably heat-activated and expands and cures upon heating, typically accomplished by gas release foaming coupled with a cross-linking chemical reaction. This structural foam is generally applied to the segments 12 in a solid or semi-solid state. The structural foam may be applied to the outer surface of the segments 12 in a fluid state casing commonly known manufacturing techniques, wherein the structural foam is heated to a temperature that permits the structural foam to flow slightly to aid in substrate wetting.
Upon curing the structural foam hardens and adheres to the outer surface of the segment 12. Alternatively, the structural foam may be applied to the segments 12 as precast pellets, which are heated slightly to permit the pellets to bond to the outer surface of the segments 12. At this stage, the structural foam is heated just enough to cause the structural foam to flow slightly, but not enough to cause the structural foam to thermally expand. Additionally, the structural foam may also be applied by heat bonding/thermoforming or by co-extrusion. Note that other stimuli activated materials capable of bonding can be used, such as; ~nrithout limitation, an encapsulated mixture of materials that, when activated by temperature, pressure, chemically, or other by other ambient conditions, will become chemically active: To this end, one aspect of the present invention is to facilitate a streamlined .
manufacturing process whereby the bonding material 14 can be placed along the segments 12 in a desired configuration and inserted within the closed form or hydroform at a point before anal assembly of the vehicle"
The bonding material 14 that may have foamable characteristics is generally an epoxy-based material, but may include an ethylene copolymer or terpolymer, such as with an alpha-olefin. As a copolymer or terpolymer, the molecule is composed of two or three different monomers, i.e., small molecules with high chemical reactivity that are capable of linking up with similar molecules. A
number of epoxy-based structural reinforcing foams are known in the art and may also be used to produce the bonding material 14 of the present invention. A typical structural foam includes a polymeric base material, such as an epoxy resin or ethylene-based polymer which, when compounded with appropriate ingredients (typically a blowing t3 Express Mail Label No. EV1'Ta319452 US
Attorney Docket No. 1001-028W0 agent and perhaps a curing agent and filler}, typically eacpands and cures in a reliable and predictable manner upon the application of heat or another activation stimulus.
The resulting material has a low density and sufficient stiffness to impart desired rigidity to a supported article. From a chemical standpoint far a thermally-activated material, the structural foam is usually initially processed as a thermoplastic material before curing. After curing, the structural foam typically becomes a thermoset material that is fixed and incapable of flowing.
An example of a preferred structural foam formulation is an ep~xy-based material that may include polymer modificis such as an ethylene copolymer or terpolymer that is commercially available from L&L Products, Inca of Romeo, Michigan, under the designations L5206, L5207, L5208 and L5209. One advantage of the preferred structural foam materials over prior art materials is the preferred materials can be processed in several ways. Possible processing techniques for the preferred materials include injection molding, extrusion or extrusion with a mini-applicator extruder. This enables the creation of part ' designs that exceed the capability of most prior art materials.
While the preferred materials for fabricating the bonding material 14 have been disclosed, the material 14 can be formed of other materials provided that the material selected is heat-activated or otherwise activated by an ambient condition (e.g. moisture, pressure, time or the like) and expands in a' predictable and reliable manner under appropriate conditions for the selected application. One such mbterial is the epoxy based resin disclosed in commonly-assigned U.S. Patent No.
6,131,897 for Structural Reinforcements, which is incorporated herein by reference. Some other possible materials ' include, but are not limited to, polyolefin materials, copolymers and terpolymers with at least one monomer type an alpha-olefin, phenollformaldehyde materials, phenoxy materials, polyurethane materials with high glass transition temperatures, and mixtures or compo sites that may include even metallic foams such as an aluminum foam composition. See also, U.S. Patent Nos.
5,766,719; 5,755,486; 5,575,526; 5,932,680 (incorporated herein by reference).
In general, the desired characteristics of the medium 14 include high stiffness, high strength, high glass transition temperature (typically greater than 70 degrees Celsius), and good adhesion retention, particularly in the presence of corrosive or high humidity environments. Still further, it is contemplated that the material 14 of the present invention could comprise a sealant, sound absorption material, or a Express Mail label No. EV1 9452 uS
Attorney Docket No. 1001-028W0 damping material used alone, or in combination with, a structural foam disposed along the plurality of segments or portions of the plurality of segments to effectuate localized structural reinforcement, sealing, andlor sound absorption along specific chosen zones of the tube 18.
In applications where a heat activated, thermally expanding material is employed, an important consideration involved with the selection and formulation of the material comprising the structural faam is the temperature at which a material reaction or expansion, and possibly curing, will take place. For instance, in most applications, it is undesirable for the material to be active at room temperature or otherwise at the ambient temperature in a production line environment. . More typically, the structural foam becomes reactive at higher processing temperatures, such as those encountered in an automobile assembly plant, when the foam is processed along with the automobile components at elevated temperatures or at higher applied energy levels: Vlihile temperatures encountered in an automobile assembly body shop ovens may be in the range of 148.89 °C to 204:44 °C (300 °F to 400 °F), and paint shop oven temps are commonly about 93.33 °C
(215 °F) or higher, if needed, blowing agents activators can be incorporated into the composition to cause expansion at different temperatures outside the above ranges.
Generally, prior art expandable acoustic foams have a range of expansion ranging from approximately 100 to over 1000 percent. The level of expansion of the bonding medium 14 may be increased to as high as .1500 percent or more, but is typically between 0°1° and 300°l°. In general, higher expansion will produce materials with lower strength and stiffness.
The modular segmented reinforcement system 10 disclosed in the present invention may be used in a variety of applications where structural reinforcement is desired. The modular segmented system 10 has particular application in those instances where the overall weight of the structure being reinforced is a critical factor. For instance, the system 10 rr,~ay be used to increase the structural strength of aircraft frames, marine vehicles, automobile framesy building structures or' other similar objects. In. the preferred embodiment disclosed, the system 10 is used as part of an automobile frame to reinforce selected areas of the automobile frame or rails, and may also be utilized in conjunction with rockers, cross-members, chassis engine cradles, radiatorlrad supports, and door impact bars in automotive vehicles with or without the use of a hydroform.
Express (~Aail Label No. EV17>!C'Ig452 US
Attorney Docket No. 1001-028WC) The system 10 is suitable for placement within a vehicle pillar, rail, rocker, or frame portion of an automobile frame assembly. At least two segments 12, and preferably a plurality of segments shaped to the contour of the chosen cavity or space defined in the automotive vehicle, are composed of an injection molded polymer (or other material (e.g., metal} or composite) provided with a suitable amount of a load transfer or bonding material 14 molded or disposed along the exterior surface or sides of the segments 12 thereby defining a plurality of porkions 16 suitable for placement within a cavity defined within an automotive vehicle, such as portions of a hydroform tube section or other area or substrate found in an automotive vehicle which could benefit from the structural reinforcement characteristics found in the present invention. In this embodiment, it will be appreciated that, the system 10 of the present invention may be used to reinforce other areas of an automobile frame or rocker assembly and the number of segments 12 and placement of the bonding material 14 along the segments 12 .would be dictated by the shape 'and desired application. .As shown in FIG. 6, it -is contemplated that the members would be flexible nested together by use of the locking or retention means 24 such as a string, clip, chain, cable, ball and socket assembly, or hitch-snap assembly which retains the segments 12 but still allows flexible movement relative to one another whereby a predetermined number of segments 12 can be utilized and shaped to fit within a defined shape and placement of an automotive vehicle application -to provide structural reinforcement of the application after activation of the bonding material 14.
Though other heat activated materials are possible, a preferred bonding material 14 is an expandable polymeric material, and preferably one that is foamable. A particularly preferred material is an epoxy-based structural foam.
For eXample, without limitation, in one embodiment, the structural foam is an epoxy-based material that may include an ethylene copolymer' or terpolymer. A number of epoxy-based structural reinforcing foams are known in the art and may also be used to produce the structural foam. A typical structural foam includes a polymeric base material, such as an epoxy resin or ethylene-based polymer which, when compounded with appropriate ingredients (typically a blowing and curing agent), .
expands and cures in a reliable and predicable manner upon the application of heat or the occurrence of a particular ambient condition. From a chemical standpoint for a thermally-activated material, the structural foam is usually initially processed as a Express Mail Label No. EV 9452 U~
Attorney Docket No. 1001-0 0 flowable thermoplastic material before curing. It will cross-fink upon curing, which makes the material incapable of further flow.
Some other possible materials include, but are not limited to, polyolefon materials, copolymers and terpolyrners with at least one monomer type an alpha-olefin, phenollformaldehyde materials, phenoxy materials, and polyurethane.
See also, U.S. Patent Nos. 5,266,133; 5,766,719; 5,755,486; 5,55,526; 5,932,680;
and WO 00127920 (PGT/US 99124795) (all of which are expressly incorporated by reference). In general, the desired characteristics of 'the resulting material include relatively high glass transition point, and good environmental degradation resistance properties. !n this manner, the material does not generally interfere with the materials systems employed by automobile manufacturers. 9Vloreover, it will withstand the processing conditions typically encountered in the manufacture of a vehicle, such as the e-coat priming, cleaning and degreasing and other coating processes, as well as the painting operations encountered in fine! vehicle assembly.
IS In another embodiment, the material 14 is pcovided in an encapsulated or partially encapsulated form, which may comprise a pellet, which includes an.
expandable foamable material, encapsulated or partially encapsulated in an adhesive shelf, which could then be attached to the members 12 in a desired configuration. An example of one such system is disclosed in commonly owned 19.S.
Patent ,No. 6,422,575 for an Expandable Pre-Formed Plug, hereby incorporated by reference. 1n addition, as discussed previously, prefarmed patterns may also be employed such as those made by extruding a sheet (having a flat or contoured surface) and then die cutting it according to a predetermined configuration.
In addition, the present inventian provides and discloses retention means for retaining the plurality of modular segmented members in position for placement directly within a selected cavity of an automotive vehicle. The retention means can consist of a number of alternative embodiments or assemblies that may be utilized as retention means for the plurality of modular segmented members. Namely, the retention means may comprise, but is not limited to: ;~ traditional ball and socket assembly as shown in FIG. T, a hitch-snap assembly as shown in FIG. 8, and a chain assembly as shown in FIG. 9.
The skilled artisan will appreciate that the system may be employed in combination with or as a component of a conventional sound blocking baffle, or a vehicle structural reinforcement system, such as is disclased in commonly owned co-Express Mail Label No. EV19452 US
Attorney Docket No. 1001 0 Q
pending U.S. Application Serial Nos. 091524,961 or 091'502,656 (hereby incorporated by reference).
A number of advantages are realized in accordance with the present invention, including, but not limited to, the ability to manufacture a structural reinforcement system for use in a hydroform or other closed form for delivery and assembly at a vehicle assembly plant without the need for application of pumpable products, wet chemical products, and multiple sets of tools, such as for other prior art.
The preferred embodiment of the present invention has been disclosed. A
person of ordinary skill in the art would realize however, that certain modifications would come within the teachings of this invention. Therefore, the following claims should be studied to determine the true scope and content of the invention.
Attorney Docket No. 1001-028W~
FIG. 9 is a perspective view of a an alternativE; embodiment of the modular segmented structural reinforcement system in accordance with the teachings of the present invention showing a plurality of modular segments held together by attachment means comprising a chain assembly which permits the flexing of at Least one modular segment relative to one another for placement in either a hydroform or directly to portions of an automotive vehicle.
DESCRIPTION OF 1'HE PREFERRED EMBODIMENT
FIG. 1 shows a modular segmented reinforcement system 10 formed in accordance with the teachings of the present inventic>n. The modular segmented reinforcement system 10 may impart increased strength, stiffness, sealing, sound absorption, or durability to a structural member or otl'7er portion of an automotive vehicle, and, thus, may be used in a variety of applications for different products.
For instance, the modular segmented reinforcement system 10 may be used as part of the frame or rail systeri~ for automobiles and building structures. Other applications of the system 10 include furniture stems, appliances, and aerospace, marine, rail, and automotive vehicles.
In a preferred embodiment, as in Fig. 2, the present invention comprises at~
least two segments 12 composed of an injection molded polymer. The.segments 12 are provided with a suitable amount of a bonding material 1~4 molded or disposed along the exterior surface or sides of the segments 12 thereby defining a plurality of segmented portions 16 wherein each portion 16 is smaller in diameter than a corresponding insertable opening in the form or tube 18. The segments 12 are modular and are capable of being shaped and sized to fit a variety of closed form applications, such as a hydroform rail. ~iowever, it is contemplated that the segments 12 can be of any geometric size, shape, and dimension corresponding to the selected area to be reinforced or damped. The plurality of segments 12 are suitable for placement within a cavity defined within an automotive vehicle, such as portions of a hydrofrom frame rail, tube section, pillar, rocker, gate, or other area or substrate found in an automotive vehicle which could benefit from the structural reinforcement characteristics found' in the present invention. In this.
embodiment, a first modular segment or portion 20 corresponds to, and is insertably attached to an opening located within a hydroform rail section or other area to be-structurally Express Mail Label No. EV19452 l!S
Attorney Docket IVo. 1001-028w0 reinforced, such as a cavity found in an automotive vehicle. A second modular segment or portion 22 is slideably engaged and affixed to a portion of the first modular segment 20. The present invention provides for a plurality of successive modular segments or portions that can be slideably engaged and affxed to one another thereby forming a unitary reinforcement system for placement within the hydroform rail or tube 18 or other cavity selected for structural reinforcement. It is contemplated that the plurality of modular segments or portions is both flexible and shapeable to the contour and shape of the desired closed form or hydroform, as well as the geometric configuration of other areas selected for reinforcement. In other words, it is contemplated that each of the plurality of segments 12 ace fVexible relative to each other so that the system 10 can be substantially formed to follow the contours of the tube 18 or other chosen portion of an automotive vehicle with or without the use of a tube 18.. Accordingly, once a first modular segment or portion 20, consisting of a segment with the bonding material 14~ placed along the segment, is positioned and slideably engaged with a second modular segment or portion 22, the now unitary first 20 and second 22 modular segments or portions provide a degree of movement or flexibility . relative - to one another thereby providing reinforcement along the contours and specific shape of the hydroform which cannot be achieved through injection molding, sheet metal applications, or other processes disclosed in the prior art. A locking or retaining member 24, which can comprise an additional segment, portion, or retention means or assembly, is then utilized to fixedly bridge the at least first 20 and second 22 segments or portions together.
Although a ball and socket feature well known in the art is shown as the locking member or means in FIG. 7, it is contemplated that locking member 24 could be shaped and configured to position and retain any number of a plurality of segments or portions and that the present invention simply discloses at least two segments or portions for illustrative purposes only and should not be limited to the number of modular segments and corresponding flexible shapes that may be desirable in a variety of applications. In addition, the locking member or retention means 24 could comprise a traditional string, wire, or cable looped or tied through each of the plurality of modular segments thereby retaining the modular segments in a desired position or simply to achieve retention of the segments 12 or portions 16 in a flexible or accordion-like state whereby each segment 12 or portion 16 could move relative to each other for placement within a defined shape or cavity of an automotive vehicle Express Mail Label No. EV19452 US
Attorney Docket No. 1001-028Wn which .does not utilize a tube or form, as shown in FIGS. 8-9. In this regard, the bonding material 14 disposed along the exterior surface or sides of the segments 12, once activated to accomplish expansion through the application of heat typically encountered in an automotive e-coat oven or other heating operation, positions and locks the plurality of segments in space along the walls of the tube or portion of the automotive vehicle defining the cavity. The resulting structure may include the wall structure joined to the plurality of segments with the aid of the activated material 14.
It is contemplated that the material 14 could be applied to the exterior surface or sides of each of the plurality of modular segments in a variety of patterns, shapes, and thicknesses to accommodate the particular size, shape, and dimensions of the cavity corresponding to the chosen form or vehicle application. In addition, each of the plurality of segments could provide a versatile function depending upon the chosen hydroform application. For example, the bonding material 14 could comprise a sealing material, a sound absorption material, a damping material, or a structural reinforcement material. These different variations of the bonding vmaterial 14~ could be placed alone or in combination on different segments or different portions of segments to achieve a desired localized result along tl~e tube 18,. such as localized structural reinforcement, localized sealing, andlor localized sound damping.
The material 14 is activated to accomplish expansion through the application of heat typically encountered in an automotive e-coat oven or other heating operation in the space defined between the plurality of segments and the walls of the hydroform tube or the portion of the.vehicle defining the cavity. The resulting structure includes the wall structure of the hydroform tube or cavity joined to the plurality of segments with the aid of the chosen material 14.
In one embodiment, at least two of the modular segments and, as shown, the first 20 and second 22 segments are nested together within the hydroform tube with each having an application of the bonding material 14. A locking member 24, which is suitable for receiving an amount of bonding material 14 along one or more of its exterior or outer surfaces, is then either placed into contact with the first 20 and second 22 segments or insertably engaged through the hydroform tube 18 to serve as a locking and positioning member of the reinforcement system. Structural reinforcement of the hydroform tubs 18 is achieved through activation by 'heat or some other activation stimulus or source of energy applied to the material 14 disposed along at feast the first 20 and second 22 modular segments wherein the Express Mail Label No. EV1 8452 US
Attorney Docket No. 1001-028W~
material 14 may expand and will structurally adhere the at least two modular segments 20 and 22, and the locking member. 24 to each other and the hydroform tube 18.
In a preferred embodiment, it is contemplated that the bonding material 14 comprises a structural foam, which is more preferably heat-activated and expands and cures upon heating, typically accomplished by gas release foaming coupled with a cross-linking chemical reaction. This structural foam is generally applied to the segments 12 in a solid or semi-solid state. The structural foam may be applied to the outer surface of the segments 12 in a fluid state casing commonly known manufacturing techniques, wherein the structural foam is heated to a temperature that permits the structural foam to flow slightly to aid in substrate wetting.
Upon curing the structural foam hardens and adheres to the outer surface of the segment 12. Alternatively, the structural foam may be applied to the segments 12 as precast pellets, which are heated slightly to permit the pellets to bond to the outer surface of the segments 12. At this stage, the structural foam is heated just enough to cause the structural foam to flow slightly, but not enough to cause the structural foam to thermally expand. Additionally, the structural foam may also be applied by heat bonding/thermoforming or by co-extrusion. Note that other stimuli activated materials capable of bonding can be used, such as; ~nrithout limitation, an encapsulated mixture of materials that, when activated by temperature, pressure, chemically, or other by other ambient conditions, will become chemically active: To this end, one aspect of the present invention is to facilitate a streamlined .
manufacturing process whereby the bonding material 14 can be placed along the segments 12 in a desired configuration and inserted within the closed form or hydroform at a point before anal assembly of the vehicle"
The bonding material 14 that may have foamable characteristics is generally an epoxy-based material, but may include an ethylene copolymer or terpolymer, such as with an alpha-olefin. As a copolymer or terpolymer, the molecule is composed of two or three different monomers, i.e., small molecules with high chemical reactivity that are capable of linking up with similar molecules. A
number of epoxy-based structural reinforcing foams are known in the art and may also be used to produce the bonding material 14 of the present invention. A typical structural foam includes a polymeric base material, such as an epoxy resin or ethylene-based polymer which, when compounded with appropriate ingredients (typically a blowing t3 Express Mail Label No. EV1'Ta319452 US
Attorney Docket No. 1001-028W0 agent and perhaps a curing agent and filler}, typically eacpands and cures in a reliable and predictable manner upon the application of heat or another activation stimulus.
The resulting material has a low density and sufficient stiffness to impart desired rigidity to a supported article. From a chemical standpoint far a thermally-activated material, the structural foam is usually initially processed as a thermoplastic material before curing. After curing, the structural foam typically becomes a thermoset material that is fixed and incapable of flowing.
An example of a preferred structural foam formulation is an ep~xy-based material that may include polymer modificis such as an ethylene copolymer or terpolymer that is commercially available from L&L Products, Inca of Romeo, Michigan, under the designations L5206, L5207, L5208 and L5209. One advantage of the preferred structural foam materials over prior art materials is the preferred materials can be processed in several ways. Possible processing techniques for the preferred materials include injection molding, extrusion or extrusion with a mini-applicator extruder. This enables the creation of part ' designs that exceed the capability of most prior art materials.
While the preferred materials for fabricating the bonding material 14 have been disclosed, the material 14 can be formed of other materials provided that the material selected is heat-activated or otherwise activated by an ambient condition (e.g. moisture, pressure, time or the like) and expands in a' predictable and reliable manner under appropriate conditions for the selected application. One such mbterial is the epoxy based resin disclosed in commonly-assigned U.S. Patent No.
6,131,897 for Structural Reinforcements, which is incorporated herein by reference. Some other possible materials ' include, but are not limited to, polyolefin materials, copolymers and terpolymers with at least one monomer type an alpha-olefin, phenollformaldehyde materials, phenoxy materials, polyurethane materials with high glass transition temperatures, and mixtures or compo sites that may include even metallic foams such as an aluminum foam composition. See also, U.S. Patent Nos.
5,766,719; 5,755,486; 5,575,526; 5,932,680 (incorporated herein by reference).
In general, the desired characteristics of the medium 14 include high stiffness, high strength, high glass transition temperature (typically greater than 70 degrees Celsius), and good adhesion retention, particularly in the presence of corrosive or high humidity environments. Still further, it is contemplated that the material 14 of the present invention could comprise a sealant, sound absorption material, or a Express Mail label No. EV1 9452 uS
Attorney Docket No. 1001-028W0 damping material used alone, or in combination with, a structural foam disposed along the plurality of segments or portions of the plurality of segments to effectuate localized structural reinforcement, sealing, andlor sound absorption along specific chosen zones of the tube 18.
In applications where a heat activated, thermally expanding material is employed, an important consideration involved with the selection and formulation of the material comprising the structural faam is the temperature at which a material reaction or expansion, and possibly curing, will take place. For instance, in most applications, it is undesirable for the material to be active at room temperature or otherwise at the ambient temperature in a production line environment. . More typically, the structural foam becomes reactive at higher processing temperatures, such as those encountered in an automobile assembly plant, when the foam is processed along with the automobile components at elevated temperatures or at higher applied energy levels: Vlihile temperatures encountered in an automobile assembly body shop ovens may be in the range of 148.89 °C to 204:44 °C (300 °F to 400 °F), and paint shop oven temps are commonly about 93.33 °C
(215 °F) or higher, if needed, blowing agents activators can be incorporated into the composition to cause expansion at different temperatures outside the above ranges.
Generally, prior art expandable acoustic foams have a range of expansion ranging from approximately 100 to over 1000 percent. The level of expansion of the bonding medium 14 may be increased to as high as .1500 percent or more, but is typically between 0°1° and 300°l°. In general, higher expansion will produce materials with lower strength and stiffness.
The modular segmented reinforcement system 10 disclosed in the present invention may be used in a variety of applications where structural reinforcement is desired. The modular segmented system 10 has particular application in those instances where the overall weight of the structure being reinforced is a critical factor. For instance, the system 10 rr,~ay be used to increase the structural strength of aircraft frames, marine vehicles, automobile framesy building structures or' other similar objects. In. the preferred embodiment disclosed, the system 10 is used as part of an automobile frame to reinforce selected areas of the automobile frame or rails, and may also be utilized in conjunction with rockers, cross-members, chassis engine cradles, radiatorlrad supports, and door impact bars in automotive vehicles with or without the use of a hydroform.
Express (~Aail Label No. EV17>!C'Ig452 US
Attorney Docket No. 1001-028WC) The system 10 is suitable for placement within a vehicle pillar, rail, rocker, or frame portion of an automobile frame assembly. At least two segments 12, and preferably a plurality of segments shaped to the contour of the chosen cavity or space defined in the automotive vehicle, are composed of an injection molded polymer (or other material (e.g., metal} or composite) provided with a suitable amount of a load transfer or bonding material 14 molded or disposed along the exterior surface or sides of the segments 12 thereby defining a plurality of porkions 16 suitable for placement within a cavity defined within an automotive vehicle, such as portions of a hydroform tube section or other area or substrate found in an automotive vehicle which could benefit from the structural reinforcement characteristics found in the present invention. In this embodiment, it will be appreciated that, the system 10 of the present invention may be used to reinforce other areas of an automobile frame or rocker assembly and the number of segments 12 and placement of the bonding material 14 along the segments 12 .would be dictated by the shape 'and desired application. .As shown in FIG. 6, it -is contemplated that the members would be flexible nested together by use of the locking or retention means 24 such as a string, clip, chain, cable, ball and socket assembly, or hitch-snap assembly which retains the segments 12 but still allows flexible movement relative to one another whereby a predetermined number of segments 12 can be utilized and shaped to fit within a defined shape and placement of an automotive vehicle application -to provide structural reinforcement of the application after activation of the bonding material 14.
Though other heat activated materials are possible, a preferred bonding material 14 is an expandable polymeric material, and preferably one that is foamable. A particularly preferred material is an epoxy-based structural foam.
For eXample, without limitation, in one embodiment, the structural foam is an epoxy-based material that may include an ethylene copolymer' or terpolymer. A number of epoxy-based structural reinforcing foams are known in the art and may also be used to produce the structural foam. A typical structural foam includes a polymeric base material, such as an epoxy resin or ethylene-based polymer which, when compounded with appropriate ingredients (typically a blowing and curing agent), .
expands and cures in a reliable and predicable manner upon the application of heat or the occurrence of a particular ambient condition. From a chemical standpoint for a thermally-activated material, the structural foam is usually initially processed as a Express Mail Label No. EV 9452 U~
Attorney Docket No. 1001-0 0 flowable thermoplastic material before curing. It will cross-fink upon curing, which makes the material incapable of further flow.
Some other possible materials include, but are not limited to, polyolefon materials, copolymers and terpolyrners with at least one monomer type an alpha-olefin, phenollformaldehyde materials, phenoxy materials, and polyurethane.
See also, U.S. Patent Nos. 5,266,133; 5,766,719; 5,755,486; 5,55,526; 5,932,680;
and WO 00127920 (PGT/US 99124795) (all of which are expressly incorporated by reference). In general, the desired characteristics of 'the resulting material include relatively high glass transition point, and good environmental degradation resistance properties. !n this manner, the material does not generally interfere with the materials systems employed by automobile manufacturers. 9Vloreover, it will withstand the processing conditions typically encountered in the manufacture of a vehicle, such as the e-coat priming, cleaning and degreasing and other coating processes, as well as the painting operations encountered in fine! vehicle assembly.
IS In another embodiment, the material 14 is pcovided in an encapsulated or partially encapsulated form, which may comprise a pellet, which includes an.
expandable foamable material, encapsulated or partially encapsulated in an adhesive shelf, which could then be attached to the members 12 in a desired configuration. An example of one such system is disclosed in commonly owned 19.S.
Patent ,No. 6,422,575 for an Expandable Pre-Formed Plug, hereby incorporated by reference. 1n addition, as discussed previously, prefarmed patterns may also be employed such as those made by extruding a sheet (having a flat or contoured surface) and then die cutting it according to a predetermined configuration.
In addition, the present inventian provides and discloses retention means for retaining the plurality of modular segmented members in position for placement directly within a selected cavity of an automotive vehicle. The retention means can consist of a number of alternative embodiments or assemblies that may be utilized as retention means for the plurality of modular segmented members. Namely, the retention means may comprise, but is not limited to: ;~ traditional ball and socket assembly as shown in FIG. T, a hitch-snap assembly as shown in FIG. 8, and a chain assembly as shown in FIG. 9.
The skilled artisan will appreciate that the system may be employed in combination with or as a component of a conventional sound blocking baffle, or a vehicle structural reinforcement system, such as is disclased in commonly owned co-Express Mail Label No. EV19452 US
Attorney Docket No. 1001 0 Q
pending U.S. Application Serial Nos. 091524,961 or 091'502,656 (hereby incorporated by reference).
A number of advantages are realized in accordance with the present invention, including, but not limited to, the ability to manufacture a structural reinforcement system for use in a hydroform or other closed form for delivery and assembly at a vehicle assembly plant without the need for application of pumpable products, wet chemical products, and multiple sets of tools, such as for other prior art.
The preferred embodiment of the present invention has been disclosed. A
person of ordinary skill in the art would realize however, that certain modifications would come within the teachings of this invention. Therefore, the following claims should be studied to determine the true scope and content of the invention.
Claims (14)
1. A system for reinforcement of a cavity defined in an automotive vehicle in response to an external load, comprising:
(a) a plurality of individual segments successively and flexibly placed relative to each other within a defined portion of the cavity of the automotive vehicle; and (b) an expandable bonding material, suitable for expansion when exposed to a heat energy source, which upon expansion helps distribute load over segments in response to the load, and being carried by the segments.
(a) a plurality of individual segments successively and flexibly placed relative to each other within a defined portion of the cavity of the automotive vehicle; and (b) an expandable bonding material, suitable for expansion when exposed to a heat energy source, which upon expansion helps distribute load over segments in response to the load, and being carried by the segments.
2. The system of claim 1, further comprising means for retaining the segments relative to each other.
3. The system of claims 1 or 2, wherein the cavity is defined in a hydroformed tube.
4. The system of any of claims 1 to 3, wherein the bonding material is a sealing material.
5. The system as claimed in any of claims 1 to 4, wherein the bonding material is an epoxy-based polymer having foamable characteristics.
6. The system as claimed in any of claims 1 to 5, wherein the bonding material is an expandable foam that is generally free of tack to the touch.
7. The system as claimed in any of claims 1 to 6, wherein the plurality of segments are adapted for reinforcing a vehicle frame rail.
8. The system as claimed in any of claims 1 to 6, wherein the plurality of segments are adapted for reinforcing a vehicle cross member.
9. The system as claimed in any of claims 1 to 6, wherein the plurality of segments are adapted for reinforcing a chassis engine cradle.
10. The system as claimed in any of claims 1 to 6, wherein the plurality of segments are adapted for reinforcing an automotive radiator support.
11. The system as claimed in any of claims 1 to 6, wherein the plurality of segments are adapted for reinforcing a door impact bar.
12. The system as claimed in any of claims 2 to 11, wherein the retaining means includes a ball and socket assembly.
13. The system as claimed in any of claims 2 to 11, wherein the retaining means includes a hitch-snap.
14. The system as claimed in claims 2 to 11, wherein the retaining means includes a chain.
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PCT/US2002/028709 WO2003026947A1 (en) | 2001-09-24 | 2002-09-09 | Structural reinforcement system having modular segmented characteristics |
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2002
- 2002-09-06 US US10/236,315 patent/US6786533B2/en not_active Expired - Lifetime
- 2002-09-09 EP EP02761604A patent/EP1320481A1/en not_active Withdrawn
- 2002-09-09 WO PCT/US2002/028709 patent/WO2003026947A1/en not_active Application Discontinuation
- 2002-09-09 MX MXPA03005259A patent/MXPA03005259A/en active IP Right Grant
- 2002-09-09 CA CA002410764A patent/CA2410764A1/en not_active Abandoned
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2004
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WO2003026947A1 (en) | 2003-04-03 |
US20040207233A1 (en) | 2004-10-21 |
MXPA03005259A (en) | 2003-10-06 |
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