Structurally reinforced panels

Abstract

A structurally reinforced panel and a method of forming the panel are disclosed. The reinforced panel includes a panel portion, a reinforcement material and a backing material disposed thereon.

1 . A structurally reinforced member for an automotive vehicle, comprising: 
 (a) a panel portion of the automotive vehicle;    (b) a reinforcement member having a length, the reinforcement member being a laminate that includes: 
 i) a reinforcement material layered upon the panel portion; and  
 ii) a backing material formed as layer and having a rib, the backing material layered upon a surface of the reinforcement material.  
   
   
   
       2 . A structurally reinforced member as in  claim 1  wherein the reinforcement material is a two-component material that activates to cure upon exposure of a first component to a second component.  
   
   
       3 . A structurally reinforced member as in  claim 1  wherein the reinforcement material is a heat activatable material that activates to foam and cure upon exposure to a temperature experienced in an e-coat or paint curing oven.  
   
   
       4 . A structurally reinforced member as in  claim 1  wherein the rib is roll formed to have an arc.  
   
   
       5 . A structurally reinforced member as in  claim 1  wherein the backing material is formed of metal.  
   
   
       6 . A structurally reinforced member as in  claim 5  wherein the backing material is at least partially formed of aluminum or steel.  
   
   
       7 . A structurally reinforced member as in  claim 1  wherein the panel portion is part of a automotive vehicle panel selected from a quarter panel, a side panel, a hood panel, a trunk panel or a door panel.  
   
   
       8 . A structurally reinforced member as in  claim 1  wherein the length is between about 30 cm and about 100 cm.  
   
   
       9 . A structurally reinforced member as in  claim 1  wherein the layer of reinforcement material has a thickness between about 3 mm and about 10 mm.  
   
   
       10 . A structurally reinforced member as in  claim 1  wherein the reinforcement material is activatable to foam and cure, but is also sufficiently tacky to adhere the layer of backing material to the panel portion prior to activation.  
   
   
       11 . A structurally reinforced member as in  claim 1  wherein the reinforcement material and the backing material are substantially coextensive along the length of the reinforcement member.  
   
   
       12 . A structurally reinforced member as in  claim 1  wherein the reinforcement member is contoured to correspond to a surface of the panel portion.  
   
   
       13 . A structurally reinforced panel for an automotive vehicle, comprising: 
 (a) a metal panel portion;    (b) a reinforcement member having a length and a width, the reinforcement member being a laminate that includes: 
 i) a reinforcement material selected from an epoxy-based material, an ethylene-based polymer, or a mixture thereof, the reinforcement material being layered upon panel portion; and  
 ii) a backing material formed of layer of metal having a metal rib extending along the length of the reinforcement member, the backing material layered upon a surface of the reinforcement material  
   wherein the length is at least twice the width and wherein the panel portion is an exterior panel of the automotive vehicle.    
   
   
       14 . A structurally reinforced member as in  claim 13  wherein the reinforcement material is a two-component material that activates to cure upon exposure of a first component to a second component.  
   
   
       15 . A structurally reinforced member as in  claim 13  wherein the reinforcement material is a heat activatable material that activates to foam and cure upon exposure to a temperature experience in an e-coat or paint curing oven.  
   
   
       16 . A structurally reinforced member as in  claim 13  wherein the rib is roll formed to have an arc and wherein the backing material is at least partially formed of aluminum or steel and wherein the panel portion is part of a automotive vehicle panel selected from a quarter panel, a side panel, a hood panel, a trunk panel or a door panel.  
   
   
       17 . A structurally reinforced member as in  claim 13  wherein the length is between about 30 cm and about 100 cm and wherein the layer of reinforcement material has a thickness between about 3 mm and about 10 mm and wherein the reinforcement material and the backing material are substantially coextensive along the length of the reinforcement member.  
   
   
       18 . A structurally reinforced member as in  claim 13  wherein the reinforcement material is activatable to foam and cure, but is also sufficiently tacky to adhere the layer of backing material to the panel portion prior to activation.  
   
   
       19 . A structurally reinforced member as in  claim 13  wherein the reinforcement member is contoured to correspond to a surface of the panel portion.  
   
   
       20 . A structurally reinforced panel for an automotive vehicle, comprising: 
 (a) a metal panel portion;    (b) a reinforcement member having a length and a width, the reinforcement member being a laminate that includes: 
 i) a reinforcement material selected from an epoxy-based material, an ethylene-based polymer, or a mixture thereof, the reinforcement material being layered upon panel portion; and  
 ii) a backing material formed of layer of metal having a roll formed metal rib extending along the length of the reinforcement member, the backing material being shaped as an elongate panel that is layered upon a surface of the reinforcement material.  
   wherein the length is at least 10 times the width;    wherein the panel portion is an exterior panel of a door of the automotive vehicle;    wherein the reinforcement material is a two component material that activates to cure upon exposure of a first component to a second component, the first component including an epoxy resin and the second component including an amine.    
   
   
       21 . A structurally reinforced member as in  claim 20  wherein the rib is roll formed to have an arc and wherein the backing material is at least partially formed of aluminum or steel and wherein the length is between about 30 cm and about 100 cm and the layer of reinforcement material has a thickness between about 3 mm and about 10 mm and wherein the reinforcement material and the backing material are substantially coextensive along the length of the reinforcement member and wherein the reinforcement member is contoured to correspond to a surface of the panel portion.