Room temperature foaming and curing carrier

Abstract

A structural carrier includes a foam core and an outer layer, the foam core and the outer layer being free of structural reinforcement ribs and open grooves, where the structural carrier is curable at a temperature of about 0 DEG C to about 50 DEG C. The structural carrier may also foam at room temperature. The structural carrier may have an adhesive material disposed on at least a portion of the outer layer.

Description

Technical Field

[0001] This teaching generally relates to a structural carrier, and more specifically, a structural carrier that bubbles and cures at room temperature. Background Technology

[0002] In the transportation and construction industries, epoxy-based adhesives and foams are frequently used to provide structural support, sealing, sound absorption, or combinations thereof. For the curing and expansion of such adhesives and foams, separate curing agents and foaming agents may often be required, increasing manufacturing costs and time. Additionally, flame retardancy of adhesives and foams may often be desired, necessitating additional additives to impart this property. Furthermore, adhesives and foams often require higher temperatures to achieve curing, activation, or both.

[0003] Furthermore, in the transportation and construction industries, epoxy-based adhesives and foams may frequently require one or more reinforcing features to provide adequate structural integrity. For example, epoxy-based adhesives and foams may often be supported or arranged on one or more carriers to improve structural integrity, stiffness, installation capability, or a combination thereof. These carriers and adhesive / foam combinations may require specific tooling operations and complex designs to ensure proper fabrication. As a result, reinforced components may require significant time, development, and cost to achieve suitable performance.

[0004] Examples of structural components can be found in U.S. Patents 7,111,899, 7,374,219, 7,790,280, and 8,127,506, all of which are incorporated herein by reference for all purposes. Alternative adhesives and foam materials are still needed for the manufacture of structural carriers. What is needed are room-temperature curable and / or foamable structural carrier materials. A structural carrier with a simplified structure is still needed. What is needed is a structural carrier free from secondary or additional reinforcing features such as ribs, grooves, or both. Simplified materials are still needed for the manufacture of structural carriers. What is needed is a structural carrier free from secondary foaming agents, secondary curing agents, glass fiber reinforcements, or combinations thereof. Summary of the Invention

[0005] This teaching satisfies one or more of the present needs by providing a structural carrier comprising: a foam core and an outer layer, wherein the foam core and the outer layer are free of structural reinforcing ribs and open grooves, wherein the structural carrier is curable at a temperature of about 0°C to about 50°C.

[0006] This teaching satisfies one or more of the present needs by providing a structural carrier wherein: the foam core and the outer layer are integrally formed; the structural carrier is a solid foam material; an adhesive is disposed on at least a portion of the outer layer; the structural carrier has an elastic modulus of about 20 MPa to 8,000 MPa; the adhesive extends co-existing with the structural carrier; the structural carrier is formed of one or more phosphate esters; the structural carrier foams at room temperature; wherein the structural carrier is free of any foaming agent, curing agent, or both; the outer layer is an adhesive and the core is a solid foam material; the structural carrier cures at room temperature, and the adhesive is a heat-activated adhesive that is curable above 50°C; the structural carrier is flame-retardant; the structural carrier is formed of one or more epoxy resins and one or more phosphate esters, wherein the structural carrier foams and cures at room temperature; the structural carrier is formed of a material comprising one or more phosphate esters and polyurethane; the one or more phosphate esters include phosphate esters derived from cashew nut shell liquid (CNSL); the structural carrier is free of any glass fiber reinforcement material; the structural carrier is free of any mechanical fasteners; the structural carrier is a structural reinforcement in a transport vehicle; or a combination thereof.

[0007] This teaching satisfies one or more of the present needs by providing a method for forming a structural carrier, the method comprising: (a) molding the outer layer; and (b) spraying foam into the outer layer to form the foam core, wherein the outer layer may be a blow-molded adhesive material that cures at a temperature greater than about 50°C.

[0008] This teaching satisfies one or more of the present needs by providing a method for forming a structural carrier, the method comprising: (a) forming the foam core into a desired shape using one or more sprayable foaming materials; and (b) casting, overmolding, pressing, or applying an adhesive material, or a combination thereof, onto the foam core along at least a portion thereof.

[0009] This teaching satisfies one or more of these needs by providing: a structural carrier having a simplified structure; a structural carrier without secondary or additional reinforcing features such as ribs, grooves, or both; a simplified material for manufacturing the structural carrier; a structural carrier without secondary foaming agents, secondary curing agents, glass fiber reinforcements, or combinations thereof; or combinations thereof. Attached Figure Description

[0010] Figure 1 This is a cross-sectional view of the carrier according to this teaching.

[0011] Figure 2 This is a perspective view of the carrier according to this teaching.

[0012] Figure 3 This is a perspective view of the carrier according to this teaching.

[0013] Figure 4 A perspective view of a carrier having an adhesive partially arranged on the surface of the carrier, in accordance with this teaching.

[0014] Figure 5 A comparison chart of the carrier modules according to this teaching.

[0015] Figure 6 A comparison chart of the carrier modules according to this teaching.

[0016] Figure 7 A diagram illustrating the flexural strength of the carrier according to this teaching.

[0017] Figure 8A This is a diagram illustrating the strength of a carrier cured using a baking process.

[0018] Figure 8B This is a graph illustrating the strength of a carrier cured at room temperature.

[0019] Figure 9 This is a diagram illustrating the strength of various carriers according to this teaching.

[0020] Figure 10A This diagram illustrates the energy absorption of a carrier cured using a baking process.

[0021] Figure 10B This diagram illustrates the energy absorption of the carrier during the baking process.

[0022] Figure 11A This is a diagram illustrating the energy absorption of a carrier that cures at room temperature.

[0023] Figure 11B This is a diagram illustrating the energy absorption of a carrier that cures at room temperature.

[0024] Figure 11C This is a graph illustrating the energy absorption efficiency of a carrier that cures at room temperature. Detailed Implementation

[0025] The explanations and illustrations presented herein are intended to enable those skilled in the art to understand the invention, its principles, and its practical applications. Those skilled in the art can modify and apply the teachings in numerous forms, which may best suit practical application needs. Accordingly, the specific embodiments of the teachings illustrated herein are not intended to be exhaustive or limiting. Therefore, the scope of the teachings should not be determined by reference to the foregoing description, but rather by reference to the appended claims and the full scope of their equivalents. Disclosures, including those in patent applications and publications, and all references, are incorporated by reference for all purposes. Other combinations are also possible, as will be known from the following claims, which are also incorporated by reference in this written description.

[0026] This teaching relates to a carrier. The carrier may function to provide structural integrity to a vehicle, structure, or both. The carrier may function to support one or more vehicle structures, vehicle components, or both. The carrier may function to suppress sound within a structure, reduce vibrations within a structure, or both. The carrier may be configured for integration into any vehicle such as an automobile, truck, aircraft, ship, train, or a combination thereof. The carrier may be configured for any industry requiring structural reinforcement, noise suppression, vibration damping, or a combination thereof. The carrier may be used in any industry, including automotive, aviation, aerospace, residential and / or commercial real estate construction, transportation, or a combination thereof. For example, the carrier may be placed in an automobile to support and / or stiffen one or more structures and / or components of the vehicle, such as A-pillars, B-pillars, C-pillars, steering column, transmission, engine block, dashboard, console, or a combination thereof. Alternatively, or additionally, the carrier may reinforce the vehicle body. It is contemplated that this teaching may also provide a carrier with a high level of energy absorption during impact and / or operation. For example, when impacted, the carrier may absorb more than 30%, more than 50%, or more than 70% of the energy. Upon impact, the carrier can absorb less than 95%, less than 85%, or less than 80% of the energy. Therefore, it can be understood from this teaching that the carrier can beneficially improve the structure of a vehicle, thereby improving the safety, lifespan, operation, or combinations thereof of all vehicles.

[0027] The carrier can provide enhanced structural integrity for one or more components, one or more structures, or both. The carrier can enhance structural integrity during impact with one or more components, one or more structures, or both. The carrier can enhance energy absorption from direct impact, indirect impact, or both. The carrier can have increased stiffness, rigidity, or both. The carrier can have increased elasticity. Increased elasticity can enhance the torsional rigidity of the carrier, allowing it to bend more before failure (e.g., shear). The carrier can have an elastic modulus of about 20 MPa or more, about 1,000 MPa or more, or about 4,500 MPa or more. The carrier can have an elastic modulus of about 8,000 MPa or less, about 6,000 MPa or less, or about 5,000 MPa or less. The carrier can bend by about 0.5% or more, about 1% or more, or about 2% or more relative to its initial position before a force is applied. The carrier can bend by about 5% or less, about 4% or less, or about 3% or less relative to its initial position before a force is applied.

[0028] It is anticipated that the carrier can be formed into any desired shape with any desired size to meet the needs of a given application. Accordingly, the carrier may include one or more undulations, one or more steps, one or more slots, one or more wavy sections, one or more arcuate sections, one or more edges, one or more linear sections, one or more planar sections, or combinations thereof. The carrier may include one or more reinforcing features, such as ribs, corner plates, reinforcing beads, or combinations thereof. However, it is anticipated that, given the structure of the carrier, the carrier may be free of any reinforcing features. In itself, it is anticipated that the carrier may be a monolithically formed structure, and the carrier may include a substantially uniform shape free of secondary attachments and / or features.

[0029] The carrier may include one or more mounting features. The carrier may include one or more attachment features to secure the carrier to the reinforced structure. The attachment features may be mechanical attachments, adhesive attachments, or both. For example, the carrier may not contain mechanical attachments and may only include adhesive attachment features. The adhesive attachment features may be integrally formed with the carrier (i.e., intact) or may be disposed on one or more surfaces of the carrier. The carrier may be formed substantially of a single material or may be formed of multiple materials. For example, the carrier may be made of multiple materials blended together to form the carrier.

[0030] The carrier can be manufactured using a variety of technologies. The carrier can undergo molding (e.g., injection molding, blow molding, or both), stamping, extrusion, pultrusion, casting, cutting, spraying, or a combination thereof. It is anticipated that the carrier can be manufactured using simplified techniques compared to conventional structural reinforcements. Since the carrier may not contain any secondary reinforcement structures, it can be manufactured without costly and / or time-consuming secondary operations. For example, in contrast to injection molding, all or part of the carrier can undergo blow molding, thereby reducing costs, reducing manufacturing time, or both. The carrier can be manufactured in a conventional manner, shipped to the construction site, and loaded into the desired application. However, the carrier can also be provided with a method of manufacture in which the carrier can be formed and installed substantially or entirely simultaneously. For example, the carrier can be formed using a foaming spray, such that the foaming spray is sprayed directly onto or into one or more parts of the vehicle (e.g., pillars of the vehicle's cab), the foaming spray bubbling and curing in place based on the contours of the vehicle structure, and an adhesive can be placed between the cured carrier and the vehicle to finally determine the assembly. Alternatively, a secondary adhesive may not be required for the assembly. The carrier can be a strip (e.g., a user can cut a carrier of the desired length from a continuous roll of strip), can be formed by spraying (i.e., a foaming spray of phosphate ester can be sprayed onto one or more desired structures to form a carrier of reinforcement), or both.

[0031] The carrier can be adjustable to meet any required requirements of a given application. The carrier, based on the material used to manufacture it, can be adjustable. The carrier can be a polymer material, a polyamide material, or both. The carrier can be a reinforced polymer material. For example, the carrier can be reinforced using secondary materials such as glass or aramid fibers. However, it is contemplated that the carrier does not contain secondary reinforcing materials such as glass fibers. The carrier can be a thermosetting material. The carrier can be a thermoplastic material. The thermoplastic material can be an epoxy thermoplastic. Alternatively, the carrier may not contain thermosetting materials. For example, the carrier may not require elevated temperatures for curing. The carrier may include a foaming material. Similarly, the foaming may be accomplished without elevated temperatures for curing.

[0032] The curing, bubbling, or both can occur at temperatures below about 40°C, below about 30°C, below about 20°C, or below about 0°C. The curing, bubbling, or both can occur at temperatures above about 0°C, above about 10°C, or even above about 20°C. The curing, bubbling, or both can occur at temperatures from about 10°C to about 35°C. The curing, bubbling, or both can occur at about 10°C. The curing, bubbling, or both can occur at room temperature (e.g., from about 15°C to about 25°C). The curing, bubbling, or both can occur at about 23°C. The curing and bubbling can occur at different temperatures or at substantially the same temperature.

[0033] It is anticipated that the carrier can be made of a material free of secondary agents. Without the presence of secondary foaming agents, curing agents, or both, the carrier can foam, cure, or both occur. Accordingly, the carrier manufacturing process can be simplified by excluding most or all secondary additives such as foaming agents, curing agents, reinforcing additives (e.g., glass-fiber), flame-retardant additives, or combinations thereof from the carrier. In itself, the carrier can be manufactured using materials that inherently include the aforementioned material properties. Examples of materials that can form carriers of this teaching can be found in Provisional U.S. Application No. 62 / 828,691, filed April 3, 2019; and U.S. Patent Publication No. 2018 / 0037695, both of which are incorporated herein for all purposes. The carrier can be formed using one or more phosphate esters, epoxides, phosphoric acids, or combinations thereof.

[0034] The carrier may include a core. The core may function to provide the structural basis of the carrier. The core may function to enhance the structural integrity of the carrier. The core may function to suppress sound, vibration, or both. The core may be formed using any of the aforementioned manufacturing methods of the carrier. For example, the core may be a solid foamed core. The core may not contain pores, cavities, grooves, or combinations thereof inherent in the manufacturing process or crosslinking of the core during its formation. For example, the core may not contain any intentionally designed grooves that could enhance the structural integrity of a conventional carrier. The core may be any desired size and shape. The core may include one or more arcuate portions, one or more linear segments, one or more planar portions, one or more undulations, one or more ridges, one or more contours, or combinations thereof. The core may be substantially homogeneous. The core may cure, foam, or both occur at room temperature. The core may be structurally rigid or may be flexible. For example, the core may have an elastic modulus of more than about 20 MPa, more than about 1,000 MPa, or more than about 4,500 MPa. The core may have an elastic modulus of about 8,000 MPa or less, about 6,000 MPa or less, or about 5,000 MPa or less. The core may bend by about 0.5% or more, about 1% or more, or about 2% or more relative to its initial position before a force is applied to it. The core may bend by about 5% or less, about 4% or less, or about 3% or less relative to its initial position before a force is applied to it.

[0035] The core may be at least partially or completely surrounded by an outer layer. The outer layer may function as a protective layer surrounding the core. The outer layer may function as an interface between the carrier and one or more reinforced structures. The outer layer may be the outer surface of the core. For example, the core may be a solid foam material that cures at room temperature to form a solid outer layer. Alternatively, the outer layer may be a secondary material, and the core may be embedded in the outer layer. For example, the outer layer may be a blow-molded adhesive material to form a shell structure, and the core may be formed by spraying foaming material into the outer layer. In addition to the core, the outer layer may provide different material properties. Although the outer layer and the core may comprise substantially similar materials, the overall material composition of the outer layer and the core may be sufficiently different to provide different properties. For example, although both the outer layer and the core may be made of ester materials, the outer layer may be denser, harder, stronger, or a combination thereof compared to the ester material of the core, and the core may provide a higher expansion rate. In itself, this teaching advantageously provides tunable carriers to meet the requirements of a given application. Compared to the core, by modifying the outer layer, even if both the outer layer and the core include at least some overlapping material, the carrier can be adjusted to meet requirements when compared to a carrier without an outer layer, without excessive material cost or weight.

[0036] The outer layer may include one or more arcuate portions, one or more linear segments, one or more planar portions, one or more undulations, one or more ridges, one or more contours, or combinations thereof. The outer layer may include one or more attachment mechanisms or may be free of attachment mechanisms. The outer layer may be substantially uniform. For example, the outer layer may have a substantially uniform thickness throughout the outer layer or may vary along the outer layer. The outer layer may have a thickness of about 1 mm or more, about 5 mm or more, or about 10 mm or more. The outer layer may have a thickness of less than about 100 mm, less than about 50 mm, or less than about 25 mm. The outer layer may not contain any structural reinforcing elements such as ribs, corner plates, or both. The outer layer may be shaped to substantially resemble the mating surface of the reinforced structure.

[0037] The carrier may include one or more surfaces. The surfaces may function to shape the carrier and support one or more components of the vehicle, the vehicle's structure, or both. The surfaces may define the external dimensions of the carrier. The surfaces may connect to each other to form the shape of the carrier. For example, the peripheral edges of the surfaces may connect to each other to form the outer perimeter of the carrier. The surfaces may be the outer surfaces of the carrier. For example, the surfaces may be formed from the outer layer of the carrier, one or more exposed portions of the core, or both. The surfaces may vary in size and shape. The surfaces may have a uniform thickness. The surfaces may have one or more arcuate portions, one or more linear segments, or both. The surfaces may be formed monolithically (i.e., formed as a single piece without secondary adhesives or fasteners connecting the surfaces). The surfaces may form any desired shape of the carrier. For example, the surfaces may form the shape of a carrier that is substantially rectangular, square, trapezoidal, cylindrical, or a combination thereof.

[0038] An adhesive may be applied to the core, the outer layer, or both. The adhesive may function to secure the carrier to one or more additional carriers, reinforced structures, or both. For example, the adhesive may secure the carrier within the structure of a vehicle pillar. The adhesive may be applied to one or more surfaces of the core, one or more surfaces of the outer layer, or both. The adhesive may be applied to one or more surfaces of the carrier. The adhesive may extend along with one or more portions of the carrier. The adhesive may extend beyond the periphery of the carrier. The adhesive may substantially surround the carrier, the core, the outer layer, or a combination thereof. The adhesive may form an outer surface. For example, the adhesive may be cast and / or overmolded around a portion or substantially all of the core of the carrier. Alternatively, the adhesive may be blow-molded to form the outer surface, and foam may be embedded in the outer surface to form the core. The adhesive may be applied to the outer surface. The adhesive may be secured to a carrier that does not contain any secondary fasteners such as bolts, screws, nails, hooks, latches, other mechanical fasteners, or combinations thereof.

[0039] The adhesive may be curable. The adhesive may cure at elevated temperatures during manufacturing processes such as the paint baking process of a vehicle. The adhesive may cure at a temperature similar to, higher than, or both of the curing temperature of the carrier. For example, the adhesive may cure at room temperature after the vehicle's baking process and may not be affected by the baking process temperature (e.g., the adhesive may not be affected by temperatures below approximately 205 degrees Celsius). The adhesive may have a desired curing time. The curing time may be more than approximately 30 seconds, more than approximately 1 minute, or more than approximately 5 minutes. The curing time may be less than approximately 10 minutes, less than approximately 8 minutes, or less than approximately 6 minutes.

[0040] The adhesive may be applied to the carrier before it is embedded in the reinforced structure, after the carrier has been embedded in the reinforced structure, or both. The adhesive may be applied to the carrier using a variety of manufacturing techniques. The adhesive may be overmolded around part or all of the carrier. Alternatively, or additionally, the adhesive may be transferred into a mold to form around the carrier. For example, molten adhesive may be placed into a cavity such that when the carrier is pressed onto the adhesive within the cavity, the adhesive flows within the mold around the carrier, thereby at least partially covering the carrier.

[0041] Although an adhesive can be formed around the carrier using a mold, the adhesive can also be pre-formed and directly attached to the carrier. The adhesive can be formed into a desired shape and pre-cut using a die. Once cut, the adhesive can be placed on and secured to the carrier. The adhesive can be secured using fasteners, mechanical connections, or both. For example, the adhesive can be attached to the carrier using secondary fasteners such as clips, screws, nails, etc. Alternatively, the carrier can include stakes or attachment protrusions incorporated into the carrier, which secure the adhesive to the carrier. Additionally, the adhesive can be a pressure-sensitive adhesive, which does not require secondary fasteners to apply the required pressure to the carrier.

[0042] The adhesive can also be vacuum-formed around the carrier. The carrier can be arranged between heated adhesive layers. Pores can then be formed around the carrier. The pores can be evacuated to remove all air generated between the adhesive and the carrier until the adhesive is in direct contact with the carrier, thereby producing the finished carrier.

[0043] The intended use is to secure the carrier within a structure. The adhesive can be directly adhered to one or more surfaces within a cavity of a structure such as a vehicle. Once the carrier is properly placed within the cavity, the adhesive can cure to maintain the carrier's position relative to the cavity. It should be noted that the adhesive can be adhesive-based, where the carrier can be directly secured to the surface before curing. Alternatively, or additionally, the adhesive can be touch-dry at room temperature or any desired temperature. Non-adhesive adhesives can help prevent degradation of the adhesive during transport and / or installation, caused by debris or other contaminants that typically adhere to the adhesive due to its adhesiveness. Accordingly, a carrier with a non-adhesive adhesive can be placed within the structure using one or more fasteners or mechanical connections before the adhesive cures. These fasteners or mechanical connections can be temporary, securing the carrier only before the adhesive cures. After curing, the adhesive can serve as a primary means of securing the carrier within the structure.

[0044] Now turn to the attached diagram. Figure 1 A cross-sectional view of a carrier 10 is illustrated. The carrier 10 includes a core 12 substantially surrounded by an outer layer 14. The outer layer 14 includes a plurality of adjacent faces 16 forming the external structure of the carrier 10. It should be noted that the outer layer 14 and the core 12 can be integrally formed (i.e., formed entirely). For example, the outer layer 14 and the core 12 can each be formed from a single material composition (e.g., a foaming material).

[0045] The carrier 10 can be utilized in a variety of ways depending on the given application. As described herein, the carrier 10 can be pre-formed using one or more manufacturing techniques for forming the carrier 10. The carrier 10 can then be embedded into a structure (e.g., a cavity in a vehicle) and secured within the vehicle using an adhesive, one or more mechanical fasteners, or both. However, the carrier 10 can also be formed directly within the reinforced structure. Instead of pre-forming the desired shape of the carrier 10, the carrier 10 can be directly injected into the structure. Advantageously, injecting and forming the carrier 10 within a structure such as a cavity allows the carrier 10 to fill holes and / or complex structures that would otherwise be difficult or impossible to achieve using a pre-formed shape in other ways. The injected carrier 10 can be a two-component composition in which a first component A and a second component B are combined during injection. The combination of these two components can activate the carrier material, thereby providing material that adheres to and / or cures to the cavity to be filled. Thus, by eliminating assembly steps or potential problems that may arise during installation, the carrier 10, as described herein, can advantageously improve overall manufacturing time and / or cost. The carrier 10 can be formed to fill any desired shape and / or pores.

[0046] Figure 2 The illustration shows a perspective view of a carrier 10. The carrier 10 includes a core 12 substantially surrounded by an outer layer 14. The outer layer 14 includes a plurality of adjacent surfaces 16 forming the external structure of the carrier 10. It should be noted that the outer layer 14 and the core 12 can be integrally formed (i.e., formed entirely). For example, the outer layer 14 and the core 12 can each be formed from a single material composition (e.g., a foaming material). As shown, the carrier 10 can be shaped to meet any desired size. For example, the carrier 10 may include one or more corrugated or undulating surfaces, steps, transition points, or combinations thereof. However, it is contemplated that the carrier 10 may not contain any additional structural features such as ribs, corner plates, open grooves, cavities, or combinations thereof.

[0047] Figure 3 The illustration shows a perspective view of a carrier 10. The carrier 10 includes a core 12 substantially surrounded by an outer layer 14. The outer layer 14 includes a plurality of adjacent faces 16 forming the external structure of the carrier 10. It should be noted that the outer layer 14 and the core 12 can be integrally formed (i.e., completely formed). For example, the outer layer 14 and the core 12 can each be formed from a single material composition (e.g., a foaming material). As shown, the carrier 10 can be substantially rectangular, and the rectangular shape can be formed by the plurality of faces 16. The carrier 10 may also be free of any secondary mechanical attachment features, such as fasteners, clips, arms, hooks, the like, or combinations thereof. However, it is also contemplated that the carrier 10 can be secured within a desired cavity, to a desired structure, or both, via one or more mechanical attachment features.

[0048] Figure 4 A perspective view of a carrier 10 is illustrated. The carrier 10 includes a core 12 substantially surrounded by an outer layer 14. The outer layer 14 includes a plurality of adjacent faces 16 forming the external structure of the carrier 10. It should be noted that the outer layer 14 and the core 12 can be integrally formed (i.e., formed entirely). For example, the outer layer 14 and the core 12 can each be formed from a single material composition (e.g., a foaming material). As shown, the carrier 10 can be substantially rectangular and can be formed from the plurality of faces 16. As shown, an adhesive 18 can be disposed on one or more faces 16 of the carrier 10. The adhesive 18 can extend beyond a single face 16 of the carrier 10. Furthermore, the adhesive 18 can terminate at one or more ends of the carrier 10, such that the adhesive 18 and the carrier 10 extend together.

[0049] Figure 5This is a comparative chart of various carrier moduli according to this teaching. As shown, torsional finite element analysis (FEA) was performed on various sample parts in the lower C-pillar of a vehicle. The samples included conventional carriers (e.g., non-ester foamed carriers), adhesive materials, and various ester foam carriers with different elastic moduli. As shown, the percentage of torsion increases with the increased elastic modulus of the ester foam carriers. Furthermore, ester foam carriers and adhesive materials, alone or in combination, provide improved torsional strength compared to conventional carriers.

[0050] Figure 6 This is a second comparative chart of various carrier moduli according to this teaching. As shown, torsional finite element analysis (FEA) was performed on various sample parts that can be implemented in the upper C-pillar of a vehicle. The samples include conventional carriers (e.g., non-ester foamed carriers), adhesive materials, and various ester foam carriers with different elastic moduli. As shown, the percentage of torsion increases with the increased elastic modulus of the ester foam carriers. Furthermore, ester foam carriers and adhesive materials, alone or in combination, provide improved torsion compared to conventional carriers.

[0051] Figure 7 This diagram illustrates the flexural strength of a carrier 10 extending between opposing supports 22. A force (F) is applied to the carrier 10 between the supports 22. Tests were conducted on: a conventional carrier (i.e., a non-foamed carrier), an ester foam carrier having an elastic modulus of approximately 2,000 MPa, and ester foam carriers with and without adhesives having an elastic modulus of approximately 3,000 MPa. As shown, the conventional carrier exhibits the lowest flexural force at 40.9 kN, while the ester carriers all show improved flexural forces.

[0052] Figure 8A and 8B This diagram illustrates the strength of the carriers cured by baking at elevated temperatures and cured at room temperature, respectively. Tests were conducted on conventional polyamide 6 (PA6) structures (i.e., non-foaming carriers) and ester carriers as described herein. Figure 8A and 8B As shown, the ester carrier with an adhesive disposed on at least a portion of its surface is stronger and exhibits higher energy absorption (EA) compared to the conventional PA6 carrier. Figure 8A and 8B The illustrations show ester carriers with different expansion rates and varying adhesive coverage. As shown, while the strength of the ester carriers can be highly tunable for a given application, they maintain a significant improvement over conventional PA6.

[0053] Figure 9This diagram illustrates the strength of various ester carriers compared to conventional polyamide 6 (PA6) carriers and hollow metal carriers (i.e., hollow). As shown, strength properties can be improved by modifying the composition of the ester carrier. The various ester carriers tested exhibited approximately the same or better strength compared to conventional PA6 carriers. Furthermore, by modifying one or more properties of the ester carrier (e.g., expansion rate, additives, total chemical composition, etc.), ester carriers can advantageously exhibit significantly greater strength compared to hollow metal carriers or conventional PA6 carriers. It should be noted that the ester carriers tested did not contain a secondary adhesive disposed along the outer surface. The ester carrier itself acts as an adhesive to bond to one or more additional structures used for reinforcement. Thus, the ester carrier provides 100% coverage for adhesion, as the entire outer surface of the ester carrier can be considered as adhesive. Conversely, the conventional PA6 carriers tested have approximately 50% coverage along the outer surface with adhesive. As shown, the adhesive coverage between the carriers can be a key factor when determining the strength of each carrier.

[0054] Figure 10A and 10B The illustration shows the energy absorption of a carrier cured using a baking process at elevated temperatures. For example... Figure 10A As shown, compared to conventional polyamide 6 (PA6) carriers or hollow (i.e., hollow) metal carriers, ester carriers with at least partial adhesive coverage absorb more energy during impact. Energy absorption can be based on... Figure 10A Calculation of the area under various material curves in pilot tests. Similarly, such as... Figure 10B As shown, the ester support improves energy absorption by approximately 118% compared to the porous metal, and exhibits improved energy absorption compared to the PA6 support. As illustrated, the ester support advantageously provides improved energy absorption while still being able to support the applied load, 2.5 times the load near the end of the experiment.

[0055] Figure 11A and 11B The diagram illustrates the energy absorption of a carrier that cures at room temperature. (Example:) Figure 11A As shown, compared to conventional polyamide 6 (PA6) supports or hollow (i.e., hollow) metal supports, ester supports with different expansion rates (labeled 50 PhE-1 and 50 PhE-2) absorbed more energy during impact. Energy absorption can be based on... Figure 11A The area under the curves for various materials tested was calculated. Similarly, energy absorption can be further improved by changing the swelling ratio of the ester support. For example, as... Figure 11A As shown, based on different expansion rates, 50 PhE-2 exhibits improved energy absorption compared to 50 PhE-1. Similarly, as... Figure 11BAs shown, compared to voided metal, the energy absorption of ester supports with different expansion rates was improved by at least 255%, and showed improved energy absorption compared to PA6 supports. Furthermore, compared to voided metal, energy absorption could be improved by approximately 287% by varying the expansion rate of the ester support. As shown in the figure, ester support 50 PhE-2 advantageously provided improved energy absorption while still being able to support the applied load, 7.4 times the load near the end of the test. It should also be noted that, as shown in… Figure 11A During the application of the load, the peak intensity of the ester support 50 PhE-2 was not reached. Therefore, it can be understood from this teaching that the ester support with a 20% expansion rate will have a significantly higher peak intensity compared to the PA6 support and the metal support.

[0056] Figure 11C The parallel graph is shown, illustrating the diagram shown in Figure 11A and 11B The energy absorption efficiency of the carriers is shown in the figure. Essentially, the rectangular shaded area depicts the total possible energy absorption of various materials based on their peak intensities. In other words, the total amount of energy that can be absorbed is related to the material under stress at 100% of its peak intensity. As shown, even with significantly lower peak intensities, the hollow metal and PA6 (“Nylon”) carriers absorb only about 66% and about 58% of the total possible energy, respectively. Conversely, the ester carrier 50 PhE-2 not only exhibits a significantly higher peak intensity (greater than 80 kN), but also absorbs about 83% of the total possible energy. Therefore, it can be inferred that the ester carrier not only resists higher forces better, but also absorbs a given force in a more efficient manner.

[0057] Component list

[0058] 10 carriers

[0059] 12 cores

[0060] 14 outer layer

[0061] 16 sides

[0062] 18 adhesives

[0063] 22 supports

[0064] F Bending force

[0065] Any numerical values ​​listed herein include all values ​​from lower to higher values ​​in increments of one unit, provided that there is an interval of at least two units between any lower and any higher value. For example, if the specified amount of a component or a process variable such as temperature, pressure, time, etc., is defined as, for example, 1 to 90, preferably 20 to 80, more preferably 30 to 70, values ​​such as 15 to 85, 22 to 68, 43 to 51, 30 to 32, etc., are intended to be explicitly listed in this specification. For values ​​less than 1, one unit is considered to be 0.0001, 0.001, 0.01, or 0.1, as appropriate. These are merely examples of specific intent, and all possible combinations of numerical values ​​between the listed minimum and maximum values ​​are to be considered as explicitly described in this application in a similar manner.

[0066] Unless otherwise stated, all ranges include all numbers between the endpoints. The use of “about” or “approximately” with respect to ranges applies to both ends of the range. Therefore, “about 20 to 30” is intended to encompass “about 20 to about 30”, including at least the specified endpoints.

[0067] All publications, including patent applications and published articles and references, are incorporated herein by reference for all purposes. The term “consistent essentially of” describing a combination shall include the identified elements, components, groups, or steps, as well as other elements, components, groups, or steps that do not materially affect the essential and novel characteristics of the combination. The use of the terms “comprising” or “including” herein to describe combinations of elements, components, groups, or steps also covers embodiments that are substantially composed of elements, components, groups, or steps. Any attribute intended to include “may” by using the term “may” herein is optional.

[0068] Unless otherwise stated, the teaching of the term "about" or "approximately" in combination with a numerical value covers the teaching of the enumerated quantity, as well as an approximation of that quantity. For example, the teaching of "about 100" covers the teaching of 100 + / - 15.

[0069] Multiple elements, components, groups, or steps may be provided by a single integrated element, component, group, or step. Alternatively, a single integrated element, component, group, or step may be divided into multiple separate elements, components, groups, or steps. The disclosure of "a" or "an" element, component, group, or step is not intended to exclude additional elements, components, groups, or steps.

[0070] It should be understood that the above description is intended to be illustrative rather than restrictive. Many embodiments and applications, in addition to the examples provided, will be apparent to those skilled in the art upon reading the above description. Therefore, the scope of the teachings should not be determined by reference to the above description, but rather by reference to the appended claims and the full scope of their equivalents. All disclosures, including those in patent applications and publications, and all references, are incorporated herein by reference for all purposes. Any omission of any aspect of the subject matter disclosed herein in the following claims is not a declaration of waiver of such subject matter, nor should it be considered that the inventor has not considered such subject matter as part of the disclosed inventive subject matter.

Claims

1. A structural carrier, comprising: a) A foam core, wherein the foam core is a solid foam material; and b) Outer layer, the outer layer being an adhesive that completely surrounds and is directly adjacent to the foam core, and forms the outer surface of the structural carrier, such that the outer layer is adapted to serve as an interface between the structural carrier and one or more structures reinforced by the structural carrier; The foam core and the outer layer do not contain structural reinforcing ribs or open grooves; At least a portion of the structural carrier is curable at a temperature of about 0°C to about 50°C; and The structural carrier is made of a material containing one or more phosphate esters.

2. The structural carrier according to claim 1, wherein the outer layer extends together with the structural carrier.

3. The structural carrier according to claim 1 or 2, wherein the structural carrier has an elastic modulus of about 20 MPa to 8,000 MPa.

4. The structural carrier according to claim 1 or 2, wherein at least a portion of the structural carrier bubbles at room temperature.

5. The structural carrier according to claim 1 or 2, wherein the structural carrier does not contain any foaming agent, curing agent or both.

6. The structural carrier according to claim 1 or 2, wherein the foam core is cured at room temperature and the outer layer is a heat-activated adhesive that can be cured at temperatures above 50°C.

7. The structural carrier according to claim 1 or 2, wherein the structural carrier is flame retardant.

8. The structural carrier according to claim 1, wherein the material of the structural carrier comprises one or more epoxy resins; and At least the foam core of the structural carrier foams and solidifies at room temperature.

9. The structural carrier according to claim 1, wherein the material of the structural carrier includes polyurethane.

10. The structural carrier according to claim 1 or 2, wherein the one or more phosphate esters comprise phosphate esters derived from cashew nut shell liquid (CNSL).

11. The structural carrier according to claim 1 or 2, wherein the structural carrier does not contain any glass fiber reinforcement material.

12. The structural carrier according to claim 1 or 2, wherein the structural carrier does not contain any mechanical fasteners.

13. The structural carrier according to claim 1 or 2, wherein the structural carrier is a structural reinforcement in a transport vehicle.

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