METHOD AND DEVICE FOR APPLICATION OF STRUCTURAL MATERIALS

• US 20120039665A1
• Filed: 05/20/2011
• Published: 02/16/2012
• Est. Priority Date: 05/21/2010
• Status: Active Grant

• Current Assignee: Zephyros, Inc.
• Original Assignee: Zephyros, Inc.
• Inventors: Richardson, Henry E., Moore, Patrick
• Granted Patent: US 9,259,867 B2
• Time in Patent Office: Days
• US Class Current: 403/265
• CPC Class Codes: B29C 37/0085 by means of openings in the layers joining through openings B29C66/304
• CPC Class Codes: B29C 44/1214 Anchoring by foaming into a preformed part, e.g. by penetrating through holes anchoring by moulding in general B29C37/0078; outsert moulding B29C45/14344, B29C70/74
• CPC Class Codes: B29C 65/565 involving interference fits, e.g. force-fits or press-fits B29C65/66 takes precedence
• CPC Class Codes: B29C 66/30325 making use of cavities belonging to at least one of the parts to be joined
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/727 being porous, e.g. foam
• CPC Class Codes: B29C 66/73121 Viscosity
• CPC Class Codes: B29C 66/742 to metals or their alloys
• CPC Class Codes: B29K 2063/00 Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2105/04 cellular or porous
• CPC Class Codes: B29L 2031/737 Articles provided with holes, e.g. grids, sieves nets B29L2028/00
• CPC Class Codes: F16B 3/005 the key being formed by solidification of injected material joining of preformed parts by applying molten plastics B29C65/40; non-disconnectible pipe joints obtained using a hardenable filler F16L13/11
• CPC Class Codes: Y10T 403/47 Molded joint

Abstract

There is disclosed a method of applying activatable material to a member of an article of manufacture such as an automotive vehicle. According to the method, the activatable material is provided to an applicator followed by applying the activatable material to the member wherein the activatable material is attached by way of a mechanical interlock via one or more through-holes.

Claims

1. A material comprising:

a pre-activation state, and the material in the pre-activation state includes;

a viscosity and the viscosity of the material is sufficient so that a pressure of applying the material is enough to move the material through one or more through holes in an article of manufacture, and the material conforms to the one or more through holes to self-anchor the material to the article of manufacture to resist pull-though.

2. The material of claim 1, wherein the viscosity of the material is low enough so that the material will not flow unless subjected to a pressure higher than atmospheric pressure.

3. The material of claim 2, wherein the material is activatable and the activatable material includes both a solid epoxy and a liquid epoxy.

4. The material of claim 3, further including an impact modifier.

5. An article of manufacture comprising:

the material of claim 4, wherein the material is applied to the article of manufacture as a continuous bead that extends at least partially along the article of manufacture and forms a mechanical interlock with the through holes in the article of manufacture as the material is forced through one or more through holes in the article of manufacture so that the material resists being pull-through the holes, and the material spans between the plurality of through-holes.

6. The article of manufacture of claim 5, wherein the activatable material and the article of manufacture are free of any mechanical fasteners that fixedly connect the activatable material to the article of manufacture.

7. The article of manufacture of claim 5, wherein the material is applied directly to the article of manufacture via a mini applicator.

8. The article of manufacture of claim 6, wherein the mechanical interlock is created simultaneously as the activatable material is applied to the article of manufacture.

9. The article of manufacture of claim 5, wherein the continuous bead has a size in the largest dimension of between about 2 mm to 5 mm.

10. The article of manufacture of claim 6, wherein the continuous bead has a size in the largest dimension of between about 3 mm to 4 mm.

11. The article of manufacture of claim 5, wherein the material, in its pre-activation state, is dry to the touch.

12. The article of manufacture of claim 5, wherein the material, in its pre-activation state, is tacky.

13. The article of manufacture of claim 5, wherein the material when activated expands and hardens so that the material adheres;

baffles;

seals;

reduces noise, vibration, and/or harshness;

reinforces;

or a combination thereof at least two articles of manufacture together.

14. The article of manufacture of claim 5, wherein the material changes size after the material is forced through the one or more through holes so that the material resists being pulled back through the one or more holes.

15. A method comprising:

a. obtaining an article of manufacture that includes one or more through holes;

b. obtaining the material of claim 1; and

c. applying the material to the article of manufacture in a continuous bead that spans between the one or more through holes so that the material is forced through the one or more through holes forming a mechanical interlock between the article of manufacture and the material.

16. The method of claim 15, further comprising curing the material.

17. The method of claim 16, wherein the activatable material is applied directly to the article of manufacture using a mini applicator;

wherein the activatable material and the article of manufacture are free of any mechanical fasteners that fixedly connect the material to the article of manufacture.

18. The method of claim 15, further including the step of adjusting the viscosity of the material.

19. The method of claim 15, further including the step of adjusting the pressure applied to the material during the step of applying the material to the article of manufacture.

20. The method of claim 16, wherein the material is cured by exposure to UV light.