Cavity filling

• US 9,427,902 B2
• Filed: 09/14/2010
• Issued: 08/30/2016
• Est. Priority Date: 09/15/2009
• Status: Active Grant

• Current Assignee: Zephyros, Inc.
• Original Assignee: Zephyros, Inc.
• Inventors: Werner, Dietmar
• Primary Examiner(s): Wood, Ellen S
• Application Number:
  US13/395,583
• Publication Number:
  US 20120237732A1
• Time in Patent Office: 2,177 Days
• Field of Search: 296/191, 296/203.01, 296/203.03, 296/188
• US Class Current: 1/1
• CPC Class Codes: B29C 44/18 Filling preformed cavities B29C44/1204 takes precedence
• CPC Class Codes: B62D 29/002 a foamable synthetic material or metal being added in situ shaping of substances in a plastic state by foaming, in general B29C44/00
• CPC Class Codes: Y10T 428/24504 Component comprises a polymer [e.g., rubber, etc.]
• CPC Class Codes: Y10T 428/249987 With nonvoid component of specified composition

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.

Claims

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.