Structural reinforcement material, insert, and reinforced cavity comprising same

Abstract

A structural reinforcement material ( 20 ) is provided that includes a base material selected from the group consisting of thermosets, low viscosity thermoplastics with short transition phases and low viscosities, low melting point metallic alloys, and combinations thereof. At STP, the structural reinforcement material ( 20 ) is a solid or a formable dough or a mixture thereof. When heated to an activation temperature, the structural reinforcement material ( 20 ) becomes flowable into a cavity ( 10 ). Following cooling, the structural reinforcement material ( 20 ) is a solid or a thermoset with a strength sufficient to reinforce the cavity ( 10 ). A structural reinforcement insert ( 111 ) comprising the structural reinforcement material ( 20 ) is also provided, as is a reinforced cavity ( 10 ) of an automobile ( 2 ) and a method of reinforcing a cavity ( 10 ).

1 . A structural reinforcement material comprising:
 a base material selected from the group consisting of thermosets, low viscosity thermoplastics with short transition phases, low melting point metallic alloys, and combinations thereof;   wherein, at about STP, the structural reinforcement material is in a phase selected from the group consisting of solid, formable dough, and mixtures thereof;   wherein the structural reinforcement material transitions to a substantially liquid phase during heating at an activation temperature; and   wherein, following activation and cooling, the structural reinforcement material is a substantially solid and has a strength sufficient to reinforce a cavity.   
   
   
       2 . The structural reinforcement material of  claim 1  wherein the base material comprises a crystalline cyclic oligoester-based thermoset. 
   
   
       3 . The structural reinforcement material of  claim 1  wherein the base material comprises a one-component epoxy thermoset. 
   
   
       4 . The structural reinforcement material of  claim 1  wherein the base material comprises a one-component polyurethane elastomer hot melt thermoset. 
   
   
       5 . The structural reinforcement material of  claim 1   wherein the base material comprises a thermoplastic having a transition phase of from about 10 min at about 140° C. to about 30 minutes at about 195° C.   
   
   
       6 . The structural reinforcement material of  claim 1  wherein the base material comprises a thermoplastic having a transition phase of from about 10 min at about 150° C. to about 30 minutes at about 175° C. 
   
   
       7 . The structural reinforcement material of  claim 1  wherein the base material comprises a thermoplastic having a transition phase of from about 15 min at about 150° C. to about 30 minutes at about 170° C. 
   
   
       8 . The structural reinforcement material of  claim 1  wherein the base material comprises a thermoplastic having a viscosity of from about 500 mPas to about 100,000 mPas. 
   
   
       9 . The structural reinforcement material of  claim 1  wherein the base material comprises a eutectic metallic alloy. 
   
   
       10 . The structural reinforcement material of  claim 9  wherein the base material comprises a metallic alloy having a melting point of from about. 100° C. to about 190° C. 
   
   
       11 . The structural reinforcement material of  claim 9  wherein the base material comprises an alloy based on metal selected from the group consisting of Sn, In, Bi, Pb and combinations thereof. 
   
   
       12 . The structural reinforcement material of  claim 1  wherein the activation temperature ranges from at least about 120° to about 190° C. 
   
   
       13 . The structural reinforcement material of  claim 1  wherein the tensile strength is at least about 20 MPa. 
   
   
       14 . The structural reinforcement material of  claim 1  wherein the Young modulus is at least about 500 MPa. 
   
   
       15 . A method of reinforcing a cavity, comprising:
 (a) attaching a structural reinforcement material of  claim 1  to a carrier to form an insert;   (b) inserting the insert into a cavity;   (c) heating the insert to an activation temperature such that the structural reinforcement material becomes substantially liquid and flows into the cavity; and   (d) cooling the insert such that the structural reinforcement material solidifies in the cavity and adheres to at least a portion of the cavity thereby reinforcing the cavity.   
   
   
       16 . The method of  claim 15 , wherein the carrier comprises metal or plastic or a combination thereof. 
   
   
       17 . The method of  claim 15  wherein the step (a) of attaching comprises the use of a mechanical fasteners. 
   
   
       18 . The method of  claim 15  wherein the step (a) of attaching comprises the use of an adhesives. 
   
   
       19 . The method of  claim 15  further comprising a preliminary step of modifying a carrier to include at least one physical barrier to control the flow of liquid structural reinforcement material. 
   
   
       20 . The method of  claim 15  wherein the at least one physical barrier comprises structural foam. 
   
   
       21 . The method of  claim 15  wherein the cavity comprises metal. 
   
   
       22 . The method of  claim 15  wherein the cavity is within an automobile. 
   
   
       23 . A structural reinforcement insert comprising:
 (a) a carrier having a first end and a second end opposite the first end, and at least one holding area between the first end and the second end, the at least one holding area comprising structural reinforcement material secured to the holding area;   (b) the structural reinforcement material of  claim 1  wherein, following cooling after activation, the structural reinforcement material has a strength sufficient to reinforce a cavity and is in a phase selected from the group consisting of thermoset and solid;   (c) uncured expansible foam at or near the first end of the carrier; and   (d) uncured expansible foam at or near the second end of the carrier;   such that upon heating to an activation temperature, the expanded foam prevents the flow of the structural reinforcement material from the holding area to extend beyond the expanded foam.   
   
   
       24 . A structural reinforcement insert of  claim 23  wherein the holding area is a cavity in the carrier. 
   
   
       25 . A structural reinforcement insert of  claim 23  wherein the structural reinforcement material is secured in the holding area with a mechanical fastener. 
   
   
       26 . A structural reinforcement insert of  claim 23  wherein the structural reinforcement material is secured in the holding area with an adhesive. 
   
   
       27 . An automobile comprising cavity comprising the structural reinforcement insert of  claim 23 . 
   
   
       28 . A reinforced cavity, comprising:
 (a) an insert within the cavity, the insert including a holding area; and   (b) cured or solidified structural reinforcement material of  claim 1 ; wherein the cured or solidified structural reinforcement material flowed from the holding area and is adhered to at least a portion of cavity and reinforces cavity.   
   
   
       29 . The reinforced cavity of  claim 28  wherein the cavity is within a frame rail of an automobile. 
   
   
       30 . The reinforced cavity of  claim 28  wherein the cavity is within an A pillar or within a B pillar of an automobile.