Cavity filling

Patent metadata

Field	Value
Publication number	US-9427902-B2
Application number	US-201013395583-A
Country	US
Kind code	B2
Filing date	Sep 14, 2010
Priority date	Sep 15, 2009
Publication date	Aug 30, 2016
Grant date	Aug 30, 2016

Abstract

A laminar structure ( 1 ) for providing foam within cavities such as those in automobile pillars and rails is provided comprising a metal foil ( 4 ) having a central section ( 2 ) and two end sections ( 3, 4 ), the central section carrying a foamable material ( 5 ) and the end sections being securable to the flanges ( 8, 9, 15, 16 ) of the cavity forming members ( 7, 14 ). The cavity containing the foam after foaming is also provided.

First claim

The invention claimed is:

1. A cavity comprising:
two cavity defining components secured together by flanges proximate to the cavity;
a laminar structure located within the cavity defining components and comprising a metal foil having a central portion and two end portions;
wherein at least part of the central portion carries a foamable material; and
wherein at least one of the end portions is secured between the flanges at each side of the cavity.

2. A cavity according to claim 1 , wherein the cavity is formed within a vehicle.

3. A cavity according to claim 2 , wherein the cavity is found in rails, pillars or seat frames.

4. A cavity according to claim 1 , wherein the cavity forming members are metal stampings.

5. A cavity according to claim 1 , wherein the central portion carries a foamed or foamable material on both sides of the metal foil.

6. A cavity according to claim 1 , wherein both end portions are secured between the flanges at each side of the cavity.

7. A cavity according to claim 1 , wherein the foil is steel foil.

8. A cavity according to claim 1 , wherein the foamed or foamable material is attached to one or both sides of the central section of the foil.

9. A cavity according to claim 1 , wherein the foam provides sealing and/or sound absorption.

10. A cavity according to claim 1 , wherein the foam provides light weight reinforcement.

11. A cavity according to claim 1 , wherein the has a degree of expansion of from about 100% to about 3000%.

12. A cavity according to claim 1 , wherein the ends of the foil are secured between the flanges of the cavity forming members by welding and/or the use of structural adhesives.

13. A cavity according to claim 1 , wherein the ends are secured sequentially to the flanges of the first and second cavity forming member.

14. A cavity according to claim 1 , wherein the ends are secured in a single bonding operation to the flanges of the first and second cavity forming member.

15. A cavity according to claim 1 , wherein the laminar structures are produced in a joined and continuous manner comprising moulding a foamable material onto a foil at a temperature below that at which it foams and cutting the laminate to the required size and repeating the process.

16. A cavity according to claim 1 , wherein the foamable material is moulded or extruded around a moving foil.

17. A cavity according to claim 1 , wherein the laminate is pressed to the required shape prior to cutting.

18. A cavity according to claim 1 , wherein the foil has a thickness of 0.075 mm to 1 mm.

19. A cavity according to claim 1 , wherein the laminar structure includes a layer of foamable material from 1.5 mm to 10 mm thick.

20. A cavity according to claim 1 , wherein the central portion includes deformations points to enable modification of the shape of the member.

Assignees

• Werner Dietmar
• Zephyros Inc

Inventors

• Werner Dietmar

Classifications

• B29C44/18 Primary

  Filling preformed cavities {(B29C44/1204 takes precedence)} · CPC title

• Y10T428/24504

  Component comprises a polymer [e.g., rubber, etc.] · CPC title

• B62D29/002

  a foamable synthetic material or metal being added in situ (shaping of substances in a plastic state by foaming, in general B29C44/00) · CPC title

• Y10T428/249987

  With nonvoid component of specified composition · CPC title