Universal High Expandable Filling Member

Abstract

The present invention relates generally to a cavity filling system for e.g. noise reduction, sealing and/or stiffening. The cavity is part of an automotive vehicle structure. The present invention further relates to an automotive vehicle structure with a multitude of cavities and a filling system.

Claims

1. A cavity filling system comprising a structure of an automotive vehicle cavity and a filling member the filling member including: i) a carrier member comprising a first and a second surface; ii) a mass of expandable material located on the surface; of the carrier member; iii) an attachment attached to the carrier member, the expandable material or both and locating the filling member relative to one sidewall of the automotive vehicle cavity; wherein upon expansion the mass of expandable material forms a foam that occupies a volume that is at least 500% of the volume occupied by the original unexpanded mass of expandable material and the mass expands from the surface into the cavity and wherein the carrier member is elastically and/or plastically deformable so that it adapts to the shape of the cavity, preferably one sidewall of the cavity.

2. The system of claim 1, wherein the carrier member and/or the attachment means comprises pre-tensioning means.

3. The system of claim 1, wherein the mass of expandable material is provided in segments which are spaced apart.

4. The system of claim 1, wherein the carrier member has a longitudinal extension and the attachment is provided in the middle of the longitudinal extension.

5. The system of claim 1, wherein the mass is only provided on the surface that is opposite from the sidewall of the cavity.

6. The system of claim 1, wherein the mass of expandable material expands to form a foam that occupies a volume that is at least 1500% of the volume occupied by the original unexpanded mass of expandable material.

7. The system of claim 1, wherein the volume of each segment of the mass of expandable material is greater than 1 cm.sup.3 but less than 2 cm.sup.3.

8. The system of claim 1, wherein the expandable material is a heat activated thermosetting material that foams, expands and cures upon exposure to temperature in an e-coat or bake oven.

9. The system of claim 1, wherein the attachment is a fastener that extends into an opening of the structure for at least partially attaching the filling member to the structure.

10. The system of claim 1, wherein the filling members are provided as a kit of multiple identical filling members which only differ in their longitudinal extension.

11. The system of claim 1, wherein the ratio of mass in kg and length of the filling member in meters off the filling member is 5:10, preferably 6:9.5, preferably 6.25:8.33.

12. An automotive vehicle structure with a multitude of cavities and a filling system according to claim 1 in at least some of the cavities, wherein each cavity being filled comprising a multitude of holes all being normalized for the attachment.

13. An automotive vehicle structure with a multitude of cavities and a filling system in at least some of the cavities, wherein the filling members are provided as a kit of multiple identical filling members which at least partially

14. The automotive vehicle according to claim 12, wherein the ratio of mass in kg and length of the filling member in meters of all filling members of the kit is 5:10, preferably 6:9.5, preferably 6.25:8.33.

15. The automotive vehicle according to claim 12, wherein the longitudinal extension of the filling members is 0.3-1.1 Meters.

16. A method to produce a kit according to claim 10, wherein one single mold-machine is utilized for all members of the kit and wherein the mold machine is provided with chambers and wherein chambers are opened or closed depending on the desired longitudinal extension of the carrier member and/or the desired amount of expandable mass.

17. The automotive vehicle according to claim 13, wherein the ratio of mass in kg and length of the filling member in meters of all filling members of the kit is 5:10, preferably 6:9.5, preferably 6.25:8.33.

18. The automotive vehicle according to claim 13, wherein the longitudinal extension of the filling members is 0.3-1.1 meters.

19. The automotive vehicle according to claim 14, wherein the longitudinal extension of the filling members is 0.3-1.1 meters.

20. The system of claim 7, wherein the ratio of mass in kg and length of the filling member in meters off the filling member is 5:10, preferably 6:9.5, preferably 6.25:8.33.

Description

[0031] The invention is now further explained according to the Figures. These explanations apply to all embodiments of the present invention. The explanations do not limit the scope of the present invention.

[0032] FIGS. 1a-1c each depict a filling member, wherein the three depicted filling elements are a kit.

[0033] FIG. 2 shows a cross section of the filling member and the attachment means

[0034] FIG. 3 shows the filling element in a cavity

[0035] FIG. 4 shows the normalized hole for all cavities of a vehicle

[0036] FIGS. 1a-c each depict one embodiment of a filling member 1. The three embodiments 1a-c are three members of a kit. Every filling element comprises a carrier member, which is strip- or ruler-shaped carrier member 1, which has in the present case a longitudinal extension 10 of 110 mm. The carrier member 1 can be made from a plastic material, for example by extrusion or moulding. The carrier element can also be made from a metal material, preferably steel. The carrier element has a first surface 3 and an opposed second surface 4. On the first surface 3, and only here, the expandable mass 5 is provided, here in five segments, which are provided separate from each other and equidistantly along the first surface 3. The segments are here provided strip-shaped. The segments preferably have all the same width and length. In the present case 8 g of expandable material is provided. Relative to the longitudinal extension 10 in the center, attachment means 6 are provided, which fix the filling element 1 to the sidewall of a cavity, particularly prior to expansion of the expandable material. As depicted, the filling element 1 is flexible and can be deformed elastically and/or plastically, so that its shape can adapt to the shape of the cavity, particularly to the sidewall of the cavity to which the filling element is attached.

[0037] The three embodiments according to FIGS. 1a-c are all designed identically but differ in their length and by the amount of expandable material. The three embodiments are an example for a kit, which is sufficient for all filling purposes of the structure for a vehicle. Due to this identical and simple design, the cost for providing the filling elements and their stock can be reduced significantly.

[0038] FIG. 2 shows a cross section of the filling member 1 and the attachment 6. It can be seen that the carrier element comprises at both sides pre-tensioning means 8, here in the form of elastic wings. The attachment means 6 comprises here hooks 11, which are inserted into a hole 14 in the structure of the vehicle. During insertion, the hooks are first elastically compressed and, as soon as they have passed the hole expand again. The pre-tensioning means force the hook against the structure of the vehicle.

[0039] FIG. 3 shows the filling element 1 in a cavity 7 of the structure of a vehicle. It can be seen that the filling element is attached to the surface of one sidewall 12 of the cavity via the attachment means 6. Out of several different embodiments of the kit, a filling element is selected that is slightly smaller than the longitudinal extension of the cavity. The expansion limits of the expandable material is indicated by reference sign 13 and s preferably 4-30 mm. For cavities higher than that a different filling element has to be chosen.

[0040] FIG. 4 depict the normalized hole, which is identical for all cavities in the vehicle structure. The cross section of the hole is preferably square or rectangular.

LIST OF REFERENCE SIGNS

[0041] 1 filling member [0042] 2 carrier member [0043] 3 first surface [0044] 4 second surface [0045] 5 mass of expandable material [0046] 6 attachment, attachment means [0047] 7 cavity [0048] 8 pre-tensioning means [0049] 9 sidewall of the cavity 7 [0050] 10 longitudinal extension [0051] 11 hook [0052] 12 sidewall of the cavity to which the filling member 1 is attached [0053] 13 expansion limits [0054] 14 hole in the structure to fix the filling member 1