Method and device for application of structural materials

• US 9,259,867 B2
• Filed: 05/20/2011
• Issued: 02/16/2016
• Est. Priority Date: 05/21/2010
• Status: Active Grant

• Current Assignee: Zephyros, Inc.
• Original Assignee: Zephyros, Inc.
• Inventors: Richardson, Henry E., Moore, Patrick
• Primary Examiner(s): Stodola, Daniel P
• Assistant Examiner(s): McMahon, Matthew R
• Application Number:
  US13/112,102
• Publication Number:
  US 20120039665A1
• Time in Patent Office: 1,733 Days
• Field of Search: 242/65.EE, 403/267, 403/269, 403/279, 403/280, 403/281, 403/274, 403/282
• US Class Current: 1/1
• 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 method comprising:

a. obtaining an article of manufacture that includes a surface and three or more adjacent through holes;

b. obtaining a material that is viscous, flowable, and uncured, wherein the material includes an epoxy resin and has a viscosity of about 10,000 PaS or less; and

c. applying the material to the article of manufacture using a mini applicator, in a continuous bead that spans between the three or more through holes so that the material is forced through the three or more through holes forming a mechanical interlock between the article of manufacture and the material;

d. raising and lowering the pressure applied to the material throughout the step of applying the material to the article of manufacture,

wherein as the continuous bead is applied along a length of the article of manufacture;

i. a normal pressure is employed when the material is applied along the surface of the article on one side of a region surrounding at least one of the three or more through holes,

ii. the pressure is raised to at least about 1×

10⁵ Pa when applying the material in the region surrounding the at least one of the three or more through holes to force the material through the at least one of the three or more through holes, and

iii. the pressure is decreased back to the normal pressure as the material is applied to the surface of the article on an opposing side of the region surrounding the at least one of the three or more through holes;

e. exposing the material to UV light for a first cure to secure the mechanical interlock between the article of manufacture and the material, wherein the material is still capable of a final curing and expansion step.

2. The method of claim 1, further comprising performing the final curing and expansion step of the material.

3. The method of claim 2, wherein during the exposing step for the first cure and the final curing and expansion step, the material and the article of manufacture are free of any mechanical fasteners that fixedly connect the material to the article of manufacture.

4. The method of claim 2, wherein the final curing and expansion step of the material is performed by exposure to elevated temperatures.

5. The method of claim 1, further including the step of adjusting the viscosity of the material.

6. The method of claim 1, wherein the material obtained in the obtaining a material step comprises 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 the three or more through holes in the article of manufacture, and the material conforms to the three or more through holes to self-anchor the material to the article of manufacture to resist pull-through.

7. The method of claim 6, wherein during the applying step, the viscosity of the material is low enough so that the material will not flow unless subjected to a pressure higher than atmospheric pressure.

8. The method of claim 6, wherein the material obtained in the obtaining a material step is activatable and the activatable material includes both a solid epoxy and a liquid epoxy to assist in flowing of the material during the applying step.

9. The method of claim 8, wherein during the obtaining the material step, the material further includes an impact modifier.

10. The method of claim 6, wherein after the applying step the material and the article of manufacture are free of any mechanical fasteners that fixedly connect the activatable material to the article of manufacture.

11. The method of claim 6, wherein during the applying step the material is applied directly to the article of manufacture via the mini applicator.

12. The method of claim 6, wherein during the applying step the mechanical interlock is created simultaneously as the material is applied to the article of manufacture.

13. The method of claim 6, wherein the continuous bead of the applying step has a diameter in the largest dimension of between about 2 mm to 5 mm.

14. The method of claim 6, wherein the continuous bead of the applying step has a width between about 3 mm to 4 mm.

15. The method of claim 6, wherein the material after the applying step, in its pre-activation state, is dry to the touch.

16. The method of claim 6, wherein the material prior to the applying step, in its pre-activation state, is tacky.

17. The method of claim 6, wherein during the applying step the material changes size after the material is forced through the three or more through holes so that the material resists being pulled back through the one or more holes.