Multi-piece sealing and / or reinforcing element

Abstract

A structural element (100) of a vehicle, wherein the structural element (100) has a cavity with at least one longitudinal axis (L1") and a multi-piece sealing and / or reinforcing element (20 is arranged in the cavity, whereby the multi-piece sealing and / or reinforcing element (20) comprises at least a first piece (21) and a second piece (22); each of the pieces (21, 22) of the multi -piece sealing and / or element (20) comprises a carrier (21a, 22a) and at least one of the carriers comprises an expandable material (21c, 22c) arranged on the carrier (21a, 22a); whereby the multi-piece sealing and / or reinforcing element (20) is arranged and / or configured such that: in unexpanded state of the expandable material (21c, 22c), the first piece (21) and the second piece (22) are present in the form of separate parts with no material connection, and in expanded state of the expandable material (21c, 22c), the expandable material forms a material connection (MC) that mechanically connects the first piece (21) with the second piece (22).

Description

[0001] MULTI-PIECE SEALING AND / OR REINFORCING ELEMENT

[0002] Technical field

[0003] The invention relates to a structural element of a vehicle, wherein the structural element (100) has a cavity and a sealing and / or reinforcing element is arranged in the cavity. Furthermore, the invention is related to a vehicle, especially a car, a truck, a watercraft, an aircraft, comprising a structural element. A further aspect of the invention is directed to a method for producing a structural element.

[0004] Background art

[0005] Construction elements such as, for example, bodies and / or chassis of transportation and conveyance means, in particular of aquatic or terrestrial vehicles or of aircraft, in many instances have structures having cavities in order for lightweight constructions to be enabled. These cavities however cause the most varied of problems. Depending on the type of the cavity, the latter has to be sealed in order to prevent the ingress of moisture and contaminations which can lead to corrosion of the construction elements. It is often also desirable for the cavities and thus the construction element to be substantially structurally reinforced, for example to improve crash performance functions, but for the low weight to be maintained. It is often also necessary for the cavities and thus the construction elements to be stabilized in order for noises, which would otherwise be transmitted along the cavity or through the latter to be reduced. Many of these cavities have an irregular shape or tight dimensions, on account of which it becomes difficult to properly seal, reinforce, and insulate said cavities.

[0006] Sealing elements (baffles) are therefore used in particular in the automotive industry but also in the aviation and nautical industry in order for cavities to be sealed and / or to be acoustically closed off, or reinforcing elements (reinforcers) are used in order for cavities to be reinforced. In this regard, US 10,933,922 B2 (Sika Technology AG) describes for example a device for reinforcing and sealing a structural element in a motor vehicle including a reinforcing element which has a longitudinal axis and which is disposable in a cavity of the structural element, wherein the reinforcing element includes walls which extend substantially in the direction of the longitudinal axis, wherein part-regions of the walls on an external circumference of the reinforcing element form at least one strip which encircles the reinforcing element and which runs transversely to the longitudinal axis of the reinforcing element.

[0007] However, depending on the structural element to be sealed or reinforced, sealing and / or reinforcing elements can be very bulky and therefore difficult to transport and install. This is in particular true in case of sealing and / or reinforcing elements for branched and / or angled cavities such as for example sections of a vehicle body at the transition of a pillar into a roof side member or a floor side member of the vehicle body.

[0008] Thus, there is still a need for new and improved solutions that overcome the aforementioned disadvantages as far as possible.

[0009] Disclosure of the invention

[0010] It is an object of the present invention to provide an improved solution for sealing and / or reinforcing a structural element of a vehicle. Especially the solutions should facilitate transport and installation, and at the same time to achieve a good sealing and reinforcing function.

[0011] Surprisingly, it has been found that this object can be achieved by the features of claim 1. Thus, the core of the present invention is related to:

[0012] A structural element of a vehicle, wherein the structural element has a cavity with at least one longitudinal axis and a multi-piece sealing and / or reinforcing element is arranged in the cavity, especially along the longitudinal axis, whereby the multi-piece sealing and / or reinforcing element comprises at least a first piece and a second piece; each of the pieces (namely the first piece and the second piece) of the multi-piece sealing and / or element comprises a carrier and at least one of the carriers comprises an expandable material arranged on the carrier; whereby the multi-piece sealing and / or reinforcing element is arranged and / or configured such that:

[0013] - in unexpanded state of the expandable material, the first piece and the second piece are present in the form of separate parts with no material connection, and

[0014] - in expanded state of the expandable material, the expandable material forms a material connection that mechanically connects the first piece with the second piece.

[0015] The inventive solution is based on a multi-piece sealing and / or reinforcing element, which is made from at least two pieces that can be provided and installed in the cavity separately. This allows reducing and optimizing packaging size during transportation and storage. Furthermore, in particular for complex shaped cavities, installation of a multi-piece sealing and / or reinforcing element usually is much simpler when compared with complicated one- piece elements.

[0016] Nevertheless, thanks to the configuration of the multi-piece sealing and / or reinforcing element, upon expansion of the expandable material, the at least two separated parts can easily be interconnected by a material connection, e.g. by the action of heat, to produce a materially bonded unit. Surprisingly, it turned out that the performance of the multi-piece sealing and / or reinforcing element in connected state after expansion of the expandable material can be nearly as good as a corresponding one-piece sealing and / or reinforcing element. This is in particular remarkable with respect to multi-piece reinforcing elements.

[0017] Additional aspects of the invention are subject of further independent claims. Particularly preferred embodiments are outlined throughout the description, the dependent claims and the figures.

[0018] Ways of carrying out the invention

[0019] A first aspect of the present invention is directed to a structural element of a vehicle, wherein the structural element has a cavity with at least one longitudinal axis and a multi-piece sealing and / or reinforcing element is arranged in the cavity , especially along the longitudinal axis, whereby the multi-piece sealing and / or reinforcing element comprises at least a first piece and a second piece; each of the pieces of the multi-piece sealing and / or element comprises a carrier and at least one of the carriers comprises an expandable material arranged on the carrier; whereby the multi-piece sealing and / or reinforcing element is arranged and / or configured such that:

[0020] - in unexpanded state of the expandable material, the first piece and the second piece are present in the form of separate parts with no material connection, and

[0021] - in expanded state of the expandable material, the expandable material forms a material connection that mechanically connects the first piece with the second piece.

[0022] In unexpanded state of the expandable material, the first piece and the second piece are present in the form of separate parts with no material connection. Especially, in unexpanded state of the expandable material, the first piece and the second piece are mechanically disconnected, especially without any physical contact. This means that there is no direct mechanical connection between the two pieces, neither a material connection nor a positivelocking connection nor a force-locking connection. This does however not exclude the possibility of an indirect mechanical connection via components of the cavity.

[0023] However, in other embodiments, in unexpanded state of the expandable material, the first piece can for example be connected to the second piece in a positive-locking and / or forcelocking manner, especially via at least one slip joint and / or at least one slot in the first piece and / or the second piece. Also, in unexpanded state of the expandable material, the first and the second piece can be connected via a third piece in a positive-locking and / or force-locking manner. This may help to more precisely arrange the pieces in the cavity.

[0024] According to an especially preferred embodiment, the multi-piece sealing and / or reinforcing element comprises a third piece for additionally connecting the first piece with the second piece. The third piece being configured and / or arranged such that in expanded state of the expandable material, the third piece is materially connected with the first piece and the second piece by the expandable material and / or a further expandable material. In particular, the third piece comprises an expandable material. The expandable material of the first piece and / or the expandable material of the second piece preferably are arranged and / or configured such that the expandable material of the first piece, upon activation, expands towards the second piece and / or the expandable material of the second piece, upon activation, expands towards the first piece. This allows for producing a direct material bond between the at least two pieces.

[0025] According to an especially preferred embodiment, both, the carrier of the first piece and the carrier of the second piece, each comprise an expandable material arranged on the respective carrier. However, in other embodiment, only one of the pieces comprises an expandable material.

[0026] In particular, the expandable material of the first piece and the expandable material of the second piece are arranged and / or configured such that in expanded state, the expandable material of the first piece and the expandable material of the second piece are in direct contact and form a common connecting area. Thereby, a material bond between the expandable materials is formed.

[0027] In a special embodiment, at least in a subsection of the common connecting area, the expandable material of the first piece and the expandable material of the second piece interpenetrate. This results in a very strong bond between the expandable materials.

[0028] Especially, in unexpanded state, the expandable material is provided on the carrier(s) in the form of a layer, especially a layer having a thickness in the range of 1 - 5 mm, especially 2 - 4 mm.

[0029] In particular, the material connection that mechanically connects the first piece with the second piece is a butt joint. In a butt joint the ends of the first piece and the second piece are joined together without any overlap and / or interlock. This allows for a rather simple joining, but a stable connection is obtainable. Especially, in a direction of a longitudinal axis of the cavity, the first piece and the second piece are arranged one after the other in the cavity, especially such that a first face side of the first piece is arranged opposite a first face side of the second piece.

[0030] Preferably, the opposing face sides have similar, congruent and / or complementary shapes. Especially, a first face side of the first piece is complementary to the first face side of the second piece.

[0031] Especially, the first face side of the first piece and / or the first face side of the second piece are flat.

[0032] However, in another preferred embodiment, the first face side of the first piece and / or the first face side of the second piece are non -flat. For example, the opposing face side(s) are stepped, V-shaped, curved and / or domed.

[0033] For example, the first face side can have one or more bulges and / or protrusions that protrude in a direction of a longitudinal axis of the cavity towards the first face side of the second piece or vice versa. In this case, preferably, the first face side of the other piece comprises one or more complementary recessed areas that are configured for receiving the one or more bulges and / or protrusions. Such a configuration can help improving mechanical stability between the two pieces because upon expansion of the expandable materials, the contact area can be increased.

[0034] In particular, in this case, the first face side of the first piece and / or the first face side of the second piece comprise(s) the expandable material, especially both face sides comprise the expandable material. Such a configuration is ideal for obtaining a butt joint as described above.

[0035] According to a highly preferred embodiment, in unexpanded state of the expandable material, the first piece and the second piece are arranged in the cavity without touching and / or abutting against each other. In this case, there is no direct physical contact between the first piece and the second piece.

[0036] Further preferred, the first piece and the second piece are arranged such that with respect to a longitudinal axis of the cavity and in expanded state of the expandable material, there is no overlap between the carrier of the first piece and the carrier of the second piece. Such a configuration allows for example for obtaining a butt joint in a rather simple but reliable manner.

[0037] However, in another possible embodiment, the first piece and the second piece are arranged such that, with respect to a longitudinal axis of the cavity, there is an overlap between the first and the second piece. This might be helpful to increase stability of the material connection between the two pieces because the area of connection can be increased.

[0038] Irrespective of the configuration with regard to the overlap, preferably, in unexpanded state of the expandable material, there is a gap, especially an air gap, between the first piece and the second piece, especially between all neighboring pieces there is a gap. The air gap can also be called gap.

[0039] In a first possible embodiment, this gap is uniform and has a constant dimension along its length.

[0040] In a second possible embodiment, this gap is non-uniform and has non-constant dimension along its length. For example, the gap can be smaller at one end and larger at the other end, or the gap can be smaller at both ends and larger between the ends, or any other configuration.

[0041] Especially, the gap has a minimum width of 1 mm, especially 2 mm, for example 3 mm or 6 mm. Especially, the width of the gap is between 1 - 8 mm, preferably 3 - 6 mm. Such dimensions turned out to be beneficial for producing strong material connections. However, depending on the structural element, other widths might be suitable as well.

[0042] In particular, in expanded state of the expandable material, the gap is at least partly, especially fully, filled with the expandable material.

[0043] In a further preferred embodiment, the multi-piece reinforcing element comprises at least one further piece. Especially, the at least one further piece comprises a carrier and optionally a further expandable material.

[0044] Especially, the at least one further piece is configured and / or arranged such that in expanded state of the expandable material(s), the at least one further piece is materially connected with the first piece and / or the second piece by the expandable material and / or the further expandable material. If the multi-piece sealing and / or reinforcing element comprises more than two pieces, preferably, the multi-piece sealing and / or reinforcing element is arranged and / or configured such that:

[0045] - in unexpanded state of the expandable material, all of the pieces are present in the form of separate parts with no material connection, and

[0046] - in expanded state of the expandable material(s), the expandable material(s) form(s) a material connection that mechanically connects neighboring pieces.

[0047] In a special embodiment, the at least one further piece is configured and / or arranged for additionally connecting the first piece with the second piece. Such a further piece can for example be used to strengthen the connection between the first and the second piece. Thereby, the at least one further piece preferably is configured and / or arranged such that in expanded state of the expandable material, the at least one further piece is materially connected with the first piece and the second piece by the expandable material and / or the further expandable material.

[0048] Also, the at least one further piece can be connected to the first piece and / or the second piece in a positive-locking and / or force-locking manner, especially via at least one slip joint and / or at least one slot in the first piece and / or the second piece. This might help to improve the stability of the connection between the pieces and / or to facilitate positioning of the pieces inside the cavity.

[0049] Especially, the multi-piece sealing and / or reinforcing element comprises exactly two or three pieces, especially two pieces.

[0050] In principle, the cavity can have any shape. Likewise, the multi-piece sealing and / or reinforcing element can be arbitrarily shaped. However, in a preferred embodiment, the multi-piece sealing and / or reinforcing element at least in sections is complementary in shape to the cavity.

[0051] For example, the cavity is a V-shaped, L-shaped, T-shaped or I-shaped cavity. In this case, preferably the multi-piece sealing and / or reinforcing element as a whole is V, shaped, L- shaped, T-shaped or I-shaped as well. Such cavities are for example present in vehicle bodies at the transition of car pillars into floor and roof side members. Especially, the cavity is a branched and / or angled cavity.

[0052] Likewise, in a preferred embodiment, the multi-piece sealing and / or reinforcing element is branched and / or angled multi-piece sealing and / or reinforcing element.

[0053] Especially, a branched and / or angled cavity has a first section running along the at least one first longitudinal direction and a second section running in a second longitudinal direction, where the first longitudinal direction is at an angle to the second longitudinal direction, especially at an angle of 45 - 90°, in particular 70 - 90°, for example 80 - 90°. Such cavities are for example present in vehicle bodies at the transition of pillars into floor and roof side members.

[0054] Likewise a branched and / or angled multi-piece sealing and / or reinforcing element has a first section, especially a first leg, running along a first longitudinal axis and a second section, especially a second leg, running along a second longitudinal axis, where the first longitudinal axis is at an angle to the second longitudinal axis, especially at an angle of 45 - 90°, in particular 70 - 90°, for example 80 - 90°.

[0055] Thereby, for example, the first piece of the multi-piece sealing and / or reinforcing element is a branched and / or angled piece, especially a V-shaped piece, L-shaped piece or a T-shaped piece.

[0056] Preferably, the second piece, is an I-shaped piece.

[0057] Thereby, the second I-shaped piece preferably is configured and / or arranged such that its longitudinal axis runs in direction of a longitudinal axis of one of the sections of the branched and / or angled first piece. Preferably, a length of the second I-shaped piece is longer than a length of the section of the branched and / or angled first piece that is extended by the I-shaped second piece.

[0058] Thus, in this case, the first and the second pieces together form a branched and / or angled piece, especially a V-shaped, L-shaped or T-shaped unit. Thereby, preferably, the second and I-shaped piece extends one of the sections of the branched and / or angled piece, especially a V-shaped, L-shaped or T-shaped piece. In addition to the expandable material required for forming the material connection between the at least two pieces, the carriers may comprise further expandable material and / or fastening means to fix the multi-piece sealing and / or reinforcing elements inside the cavity. In particular, the carriers of the at least two pieces comprise further expandable material, which extends over at least 50%, in particular 80 - 100%, of the entire length of the pieces in longitudinal direction.

[0059] According to a special embodiment, the structural element comprises at least a section of a car pillar, especially an A-, B-, C- and / or D-pillar.

[0060] In particular, the structural element is a section of the vehicle body, especially a section at the transition of a car pillar into a roof side member or a floor side member of the vehicle body.

[0061] The multi-piece sealing and / or reinforcing elements according to the invention are highly suitable for such applications, especially when used as reinforcing elements. Reinforcing elements located at these positions in a vehicle body usually are rather large and transportation and storage is an issue. Furthermore, the elements are complex in shape making installation more demanding. Therefore, providing the reinforcing element as separate parts and joining them later on greatly simplifies the provision of the reinforcing element and its installation.

[0062] Thus, in a highly preferred embodiment, the multi-piece sealing and / or reinforcing element is a reinforcing element.

[0063] However, the inventive approach might be used for sealing and / or reinforcing any other structural element of a vehicle body.

[0064] In principle, any desired material that can be made to foam in a controlled manner can be used as the expandable material. This material may or may not have reinforcing properties. In the present case, expandable materials with reinforcing properties are preferred for forming the material connection between the at least two pieces.

[0065] The expandable material is typically configured in such a way that it can be foamed thermally, by moisture and / or by electromagnetic radiation. Such an expandable material typically comprises a chemical and / or a physical foaming agent. Chemical foaming agents are organic and / or inorganic compounds which decompose under the influence of temperature, moisture and / or electromagnetic radiation, at least one of the decomposition products being a gas. Compounds which transition into the gaseous state of aggregation when the temperature is increased may for example be used as physical foaming agents. As a result, both chemical and physical foaming agents are capable of creating foam structures in polymers.

[0066] The expandable material is preferably foamed thermally, with chemical foaming agents being used. Examples of suitable chemical foaming agents are azodicarbonamides, sulfohydrazides, hydrogen carbonates or carbonates.

[0067] Suitable foaming agents are, for example, also commercially available under the trade name Expancel@ from Akzo Nobel, the Netherlands, or under the trade name Celogen® from Chemtura Corp., USA. The heat required for the foaming can be introduced by external or by internal heat sources, such as an exothermic chemical reaction.

[0068] The expandable material is preferably foamable at a temperature of <200°C, preferably <160°C, in particular of 80°C to 150°C, preferably of 90°C to 140°C. In particular, this is over a period of time of 10-60 min. In this way, said expandable material can be foamed in already established process steps in vehicle manufacturing.

[0069] Examples of suitable expandable materials are single-component epoxy resin systems which do not flow at room temperature and in particular have an enhanced impact strength and contain thixotropic agents such as aerosils or nanoclays. For example, epoxy resin systems of this type include 20 to 50% by weight of a liquid epoxy resin, 0 to 30% by weight of a solid epoxy resin, 5 to 30% by weight of impact modifiers, 1 to 5% by weight of physical or chemical foaming agents, 10 to 40% by weight of fillers, 1 to 10% by weight of thixotropic agents and 2 to 10% by weight of heat-activatable catalysts. Suitable impact modifiers are reactive liquid rubbers based on nitrile rubber or derivatives of polyether polyol polyurethanes, core-shell polymers and similar systems known to a person skilled in the art.

[0070] Likewise suitable foamable materials are one-component polyurethane compositions containing foaming agents and based on crystalline polyesters comprising OH groups and mixed with further polyols, preferably polyether polyols, and polyisocyanates with blocked isocyanate groups. The melting point of the crystalline polyester should be >50°C. The isocyanate groups of the polyisocyanate can be blocked, for example by nucleophiles such as caprolactam, phenols or benzoxalones. Also suitable are blocked polyisocyanates such as are used, for example, in powder-coating technology and are commercially available, for example, under the trade names Vestagon® BF 1350 and Vestagon® BF 1540 from Degussa GmbH, Germany. Likewise suitable as isocyanates are so-called encapsulated or surface- deactivated polyisocyanates which are known to a person skilled in the art and are described, for example, in EP 0 204 970.

[0071] Also suitable as expandable materials are two-component epoxy / polyurethane compositions containing foaming agents, such as are described, for example, in WO 2005 / 080524 Al.

[0072] Also suitable as expandable materials are ethylene-vinyl acetate compositions containing foaming agents.

[0073] Likewise suitable expandable materials are sold, for example, under the trade name SikaBaffle® 240, SikaBaffle® 250, SikaBaffle® 255, or SikaReinforcer®-940 by Sika Corp., USA.

[0074] In one exemplary embodiment the expansion rate of the expandable material is less than 500%, or less than 400%, or less than 300%. Expandable materials which are expandable to a lesser degree usually offer the advantage that they do not lose mechanical stability to an excessive degree on expansion.

[0075] Especially, the expandable material in expanded state has an E-modulus of at least 100 MPa or of at least 150 MPa or of at least 200 MPa. The values specified with respect to the modulus of elasticity relate to the expandable material in the state of use thereof in the structural element. This means that the values are specified in particular after a possible expansion of the material and after a possible hardening of the material.

[0076] A rather low expansion rate and a high E-modulus are in particular beneficial if the multipiece sealing and / or reinforcing element is used as a multi-piece reinforcing element or a reinforcer, respectively.

[0077] Also, the expandable material can have an expansion rate of more than 500%, preferably of more than 800%, particularly preferably of more than 1500%. Especially, the expandable material in expanded state can have an E-modulus of at most 20

[0078] MPa or at most 15 MPa or at most 10 MPa.

[0079] A rather high expansion rate and a low E-modulus are in particular beneficial if the multipiece sealing and / or reinforcing element is used as a multi-piece sealing element or a baffle, respectively,

[0080] The carriers are made in particular from a non-expandable material. In the context of this invention, the expression “non-expandable” means that the volume of a material changes by not more than or by less than 10% when the process steps provided for the expanding the expandable materials are carried out. This is in particular at a temperature of up to 160°C, in particular of 80°C to 150°C, preferably of 90°C to 140°C. In comparison with the expandable material, the carrier thus expands far less to not at all and remains substantially in its original shape even in the expanded state of the expandable materials.

[0081] The carriers may consist of any desired materials. Preferred materials are plastics, in particular polyurethanes, polyamides, polyesters and polyolefins, preferably high- temperature-resistant polymers such as poly(phenylene ethers), polysulfones or polyether sulfones, which may in particular also be foamed; metals, in particular aluminium and steel; or grown organic materials, in particular wood or other (densified) fibrous materials, or glasstype or ceramic materials; especially also foamed materials of this type; or any desired combinations of these materials. Polyamide, in particular polyamide 6, polyamide 6.6, polyamide 11, polyamide 12 or a mixture thereof, is particularly preferably used.

[0082] Combinations of the aforementioned materials with fibres, such as for example glass fibres or carbon fibres, are also possible, Glass fibre-reinforced plastics (GFRP) or carbon fibre- reinforced plastics (CFRP) are particularly preferred.

[0083] Furthermore, the carriers may have any desired construction and any desired structure. For example, they may be solid, hollow and / or foamed and / or have a grid-like structure. Typically, the surface of the carriers may be smooth, rough and / or structured. Particularly preferably, the carriers are configured as V-shaped, L-shaped, T-shaped and / or I-shaped elements. The parts of the structural element other than the multi-piece sealing and / or reinforcing element may comprise or consist of metals, composite materials and / or synthetic materials. Especially, preferred are aluminum, magnesium, steel, carbon-fiber materials and / or polymeric materials.

[0084] A further aspect of the present invention is direct to a method for producing a structural element, especially a structural element as described above, comprising the steps of: a) Providing a structural element of a vehicle having a cavity with at least one longitudinal axis; b) Providing a multi-piece sealing and / or reinforcing element comprising at least a first piece and a second piece; each of the pieces (namely the first piece and the second piece) of the multi-piece reinforcing element comprising a carrier and at least one of the carriers comprises an expandable material arranged on the carrier; c) Arranging the first piece and the second piece of the multi-piece sealing and / or reinforcing element in the cavity along the longitudinal axis, such that in unexpanded state of the expandable material, the first piece and the second piece are present in the form of separate parts with no material connection; d) Expanding the expandable material such that the expandable material forms a material connection that mechanically connects the first piece with the second piece.

[0085] Preferably, in step b) the first piece and the second piece of the multi-piece sealing and / or reinforcing element are provided as physically separated parts, especially in separate packaging. This will reduce the risk of unwanted sticking together of the pieces via the expandable materials during transportation and / or storage, e.g. at high temperatures. However, the pieces can also be provided in a single packaging.

[0086] In step c), the first piece and the second piece preferably are introduced one after the other into the cavity.

[0087] A further aspect of the invention is directed to a multi-piece sealing and / or reinforcing element comprising at least a first piece and a second piece; each of the pieces of the multi-piece sealing and / or reinforcing element comprises a carrier and at least one of the carriers comprises an expandable material arranged on the carrier; whereby the multi-piece sealing and / or reinforcing element is configured such that:

[0088] - in unexpanded state of the expandable material, the first piece and the second piece are present in the form of separate parts with no material connection, especially as mechanically disconnected parts, and

[0089] - in expanded state of the expandable materials, the expandable material of the first piece and the expandable material of the second piece can form a material connection that mechanically connects the first piece with the second piece.

[0090] Especially, the multi-piece sealing and / or reinforcing element is provided as a kit-of-parts with the at least two pieces physically separated, especially in separate packaging.

[0091] Another aspect of the present invention is directed to a vehicle, especially a car, a truck, a watercraft, or an aircraft, comprising a multi-piece sealing and / or reinforcing element and / or a structural element as described above.

[0092] Furthermore, the invention is directed to a use of a multi-piece sealing and / or reinforcing element as described above for sealing and / or reinforcing a structural element of a vehicle body.

[0093] Further advantageous implementations of the invention are evident from the exemplary embodiments.

[0094] Brief description of drawings

[0095] The drawings used to explain the exemplary embodiments show:

[0096] Fig. 1 a schematic, exemplary illustration of a body of a motor vehicle;

[0097] Fig. 2 a first multi-piece reinforcing element comprising a T-shaped first piece and a separated I-shaped second piece;

[0098] Fig. 3 a second multi-piece reinforcing element with complementary and interlocking end sides; Fig. 4 a third multi-piece reinforcing element having an I-shaped first piece and a separated I-shaped second piece, whereby and additional mechanical connection is provided between the two pieces;

[0099] Fig. 5 a fourth multi-piece reinforcing element comprising three separated I-shaped pieces;

[0100] Fig. 6 a structural element of a vehicle body having T-shaped cavity before installation of a sealing and / or reinforcing element;

[0101] Fig. 7 the cavity of Fig. 6 with the first piece of the multi-piece reinforcing element of Fig. 2 being placed in the cavity;

[0102] Fig. 8 the cavity of Fig. 7 after having additionally introduced the second piece of the multi-piece reinforcing element of Fig. 2;

[0103] Fig. 9 the cavity of Fig. 8 after having expanded the expandable materials of the multipiece reinforcing element to form a material connection.

[0104] Exemplary embodiments

[0105] Fig 1. schematically illustrates a body 10 of a motor vehicle. In this context, the body 10 has various structural elements with cavities, such as for example the A-pillar 11, the B-pillar 12, the C-pillar 13, the wheel well 14, the side sill 15 or the roof side member 17. Such structural elements with cavities can now be sealed by multi -piece sealing elements 16 according to the invention, which are illustrated schematically in FIG. 1 as I-shaped elements, or be reinforced by multi -piece reinforcing elements 18 according to the invention, which are illustrated schematically in FIG. 1 as T-shaped elements.

[0106] Fig. 2 shows a first multi-piece reinforcing element 20 comprising a T-shaped first piece 21 and a separated I-shaped second piece 22. The first piece 21 has a first section running along a first longitudinal axis LI and a second section running along a second longitudinal axis L2, where the first longitudinal axis LI is at an angle to the second longitudinal axis of for example 90°. The first piece 21 comprises a carrier 21a with a first face side 21b carrying a layer of an expandable material 21c. Likewise, the second piece 22 has a carrier 22a with first face side 22b carrying a layer of an expandable material 22c. In Fig. 2 the first face side 21b of the first piece 21 and the first face side 22b of the second piece 22 are congruent. For example, both expandable materials 21c, 22c are identical in composition and the layer thicknesses are similar, e.g. 4 mm.

[0107] In Fig. 2, the expandable materials 21c, 22c are shown in unexpanded state. However, the two pieces 21, 22 are arranged with opposing faces sides 21b, 22b, such that upon activation or expansion of the expandable materials 21c, 22c, a material connection between the two pieces 21, 22 can be formed (more details about such a process are shown in Fig. 6 - 9).

[0108] Fig. 3 shows a second multi-piece reinforcing element 30 comprising a T-shaped first piece 31 and a separated I-shaped second piece 32. The first piece 31 comprises a carrier 31a with a first face side 31b that has a stepped structure. Likewise, the second piece 32 comprises a carrier 32a with a first face side 32b having a complementary stepped structure, so that the two pieces 31, 32 can be arranged with an overlap in the direction of the first longitudinal axis LI' without abutting against each other. Furthermore, in contrast to the second multi - piece reinforcing element 20, only the first piece 31 comprises an expandable material 31c at its face side 31b whereas face side 32b is free from expandable material. Otherwise, the two multi-piece reinforcing elements 20 and 30 are identical in design. Upon activation and expansion of the expandable material, the two pieces 31, 32 can be materially connected to each other.

[0109] Fig. 4 shows a third multi -piece reinforcing element 40 having an I-shaped first piece 41 and a separated I-shaped second piece 42. The first piece comprises a carrier 41a with a first face side 41b having a protrusion 41d being placed in a form-fitted manner a slot 42d located in a first face side 42b of the carrier 42a of the second piece 42. This allow the two pieces 41, 42 to be arranged in a defined distance from each other. An expandable material 42c is arranged at the face side 42b of the second piece 42 and, upon expansion, allows the two pieces 41, 42 to be materially connected.

[0110] Fig. 5 shown a fourth multi-piece reinforcing element 50 having an I-shaped first piece 51 with a carrier 51a, a separated I-shaped second piece 52 with a carrier 52a and a separated I- shaped third piece 53 with a carrier 53a. Similar to Fig. 1, the two pieces 51, 52 can be materially connected upon expansion of the expandable materials 51c, 52c, located at the opposing face sides 51b, 52b of the first piece 51 and the second piece 52. In addition, the third piece 53, which is carrying further expandable material 53c on a carrier 53a form a material bond between with the first piece 51 and with the second piece 52 and thereby interconnect the first and the second piece 51, 52 additionally.

[0111] Although not shown in Fig. 2 - 5, the carriers 21a, 22a, 31a, 32a, 41a, 42a, 51a, 52a may comprise further expandable material and / or fastening means to fix the multi-piece reinforcing elements in cavities and thereby sealing and / or reinforcing structural elements.

[0112] Fig. 6 shows a structural element 100 of a vehicle body having a T-shaped cavity 100 in the form of a branched cavity with a first section 101 running along the at least one first longitudinal direction LI" and a second section 102 running in a second longitudinal direction L2", where the first longitudinal direction LI" is at an angle to the second longitudinal direction L2", e.g. 90°. Such cavities are for example present in vehicle bodies at the transition of a B-pillar 12 into a roof side member 17 as shown in Fig. 1 (see circled area in Fig. 1).

[0113] In order to reinforce the structural element 100, the second piece 22 of the first multi-piece reinforcing element 20 shown in Fig. 2 can be introduced into the first section 101 of the cavity. The situation after introduction is shown in Fig. 7.

[0114] Subsequently, as show in Fig. 7, the first piece 21 of the first multi -piece reinforcing element 20 shown in Fig. 2 is introduced into the cavity 100. Thereby, the two pieces 21, 22 are arranged one after the other in the cavity 100, such that the expandable materials 21c, 22c of the respective pieces face each at a distance of for example 6 mm. Put differently, there is an air gap G of for example 6 mm between the two pieces 21, 22, as shown in Fig. 7. Thus, the two pieces 21, 22 do not touch each other as long as the expandable materials 21c, 22c, are in unexpanded state.

[0115] Upon activation, e.g. by heating during a process steps in vehicle manufacturing, the expandable materials 21c, 22c start to expand towards each other or along the longitudinal axis Ll / Ll". In fully expanded state, expandable materials 21c', 22c' form a material connection MC in the form of a butt joint between the two pieces 21, 22 in the cavity 100, as shown in Fig. 9. It will be appreciated by those skilled in the art that the present invention can be implemented in other specific forms without departing from the spirit or essential characteristics thereof The presently disclosed implementations and embodiments are therefore considered in all respects to be illustrative and not restricted.

Claims

Claims1. A structural element (100) of a vehicle, wherein the structural element (100) has a cavity with at least one longitudinal axis (LI") and a multi -piece sealing and / or reinforcing element (20) is arranged in the cavity, whereby the multi-piece sealing and / or reinforcing element (20) comprises at least a first piece (21) and a second piece (22); each of the first and the second piece (21, 22) of the multi -piece sealing and / or element (20) comprises a carrier (21a, 22a) and at least one of the carriers comprises an expandable material (21c, 22c) arranged on the carrier (21a, 22a); whereby the multi-piece sealing and / or reinforcing element (20) is arranged and / or configured such that: in unexpanded state of the expandable material (21c, 22c), the first piece (21) and the second piece (22) are present in the form of separate parts with no material connection, and in expanded state of the expandable material (21c, 22c), the expandable material forms a material connection (MC) that mechanically connects the first piece (21) with the second piece (22).

2. The structural element according to claim 1, whereby both, the carrier (21a) of the first piece (21) and the carrier (22a) of the second piece (22), each comprise an expandable material (21c, 22c) arranged on the respective carrier and whereby the expandable material of the first piece (21) and the expandable material of the second piece (22) are arranged and / or configured such that in expanded state, the expandable material of the first piece (21) and the expandable material of the second piece (22) are in direct contact and form a common connecting area.

3. The structural element according to any of preceding claims, whereby the expandable material of the first piece (21) and / or the expandable material of the second piece (22) is arranged and / or configured such that the expandable material (21c) of the firstpiece (21) expands towards the second piece (22) and / or the expandable material (22c) of the second piece (22) expands towards the first piece (21).

4. The structural element according to any of preceding claims, whereby the material connection (MC) that mechanically connects the first piece (21) with the second piece (22) is a butt joint.

5. The structural element according to any of preceding claims, whereby, in a direction of a longitudinal axis (LI") of the cavity, the first piece (21) and the second piece (22) are arranged one after the other in the cavity, such that a first face side (21b) of the first piece (21) is arranged opposite a first face side (22b) of the second piece (22), and, preferably, the face sides (21b, 22b) have similar, complementary and / or congruent shapes.

6. The structural element according to any of preceding claims whereby, in unexpanded state of the expandable material (21c, 22c), the first piece (21) and the second piece (22) are arranged in the cavity without touching and / or abutting against each other.

7. The structural element according to any of preceding claims, whereby in unexpanded state of the expandable material, there is an air gap (G) between the first piece (21) and the second piece (22).

8. The structural element according to any of preceding claims, whereby the first piece (21) and the second piece (22) are arranged such that with respect to a longitudinal axis (LI") of the cavity and in expanded state of the expandable material(s), there is no overlap between the carrier (21a) of the first piece (21) and the carrier (22a) of the second piece (22).

9. The structural element according to any of preceding claims, whereby the multi-piece sealing and / or reinforcing element comprises a third piece (53) for additionally connecting the first piece with the second piece, whereby the third piece being configured and / or arranged such that in expanded state of the expandable material, the third piece is materially connected with the first piece and the second piece by the expandable material and / or a further expandable material.

10. The structural element according to any of preceding claims, whereby the cavity is an angled and / or branched cavity having a first section (101) running along the at least one first longitudinal direction (11") and a second section (102) running in a second longitudinal direction (L2"), where the first longitudinal direction is at an angle to the second longitudinal direction, especially at an angle of 45 - 90°, in particular 70 - 90°, for example 80 - 90°.

11. The structural element according to any of preceding claims, whereby the multi-piece sealing and / or reinforcing element is an angled and / or branched element.

12. The structural element according to any of preceding claims, whereby the multi-piece sealing and / or reinforcing element is V-shaped, T-shaped or L-shaped.

13. The structural element according to any of preceding claims, whereby the structural element is a section of the vehicle body at the transition of a car pillar (12), especially an A-, B-, C- and / or D-pillar, into a roof side member (17) or a floor side member (15) of the vehicle body.

14. Vehicle, especially a car, a truck, a watercraft, an aircraft, comprising a structural element according to any of claims 1 - 13.

15. Method for producing a structural element, especially a structural element as described in any of preceding claims, comprising the steps of: a) providing a structural element (100) having a cavity with at least one longitudinal axis (LI"); b) providing a multi-piece sealing and / or reinforcing element (20) comprising at least a first piece (21) and a second piece (22); each of the first and the second piece of the multi -piece sealing and / or reinforcing element comprising a carrier (21a, 22a) and at least one of the carriers comprises an expandable material (21c, 22c) arranged on the carrier (21a, 22a); c) arranging the first piece (21) and the second piece (22) of the multi-piece sealing and / or reinforcing element in the cavity, such that in unexpanded state of theexpandable material, the first piece (21) and the second piece (22) are present in the form of separate parts with no material connection; d) expanding the expandable material (21c, 22c) such that the expandable material forms a material connection (MC) that mechanically connects the first piece (21) with the second piece (22).

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