Abstract:
A panel assembly (10) with a multi-layer patch (14) may be used in any number of different applications in order to reduce noise or vibrations, provide thermal insulation, and/or improve the structural integrity of an underlying part. In an exemplary embodiment where the panel assembly is a vehicle part, the panel assembly (10) includes a main panel (12), a primary adhesive layer (16), and a multi-layer patch (14) that includes at least two individual patches (24, 26, 28) and at least one auxiliary adhesive layer (30, 32). The primary adhesive layer attaches the multi-layer patch to the main panel, and the auxiliary adhesive layer attaches the individual patches together. The size, shape, thickness and/or composition of the different layers of the multi-layer patch may be specifically chosen to exhibit certain sound and/or thermal damping properties.
Abstract:
A panel assembly (10) for use in any number of different applications, including a variety of vehicle applications, that reduces noise or vibrations, provides thermal insulation, and/or improves structural integrity. According to an exemplary embodiment, the panel assembly (10) includes a main panel (12) made from a metal, one or more sound damping patches (14, 16) also made from a metal, and an adhesive layer (18) that joins the patches (14, 16) to the main panel (12) in a constrained layer construction. The sound damping patches (14, 16) may include one or more forming features (30, 32), which are designed to improve the formability of the panel assembly (10) without significantly impairing its sound damping characteristics. There are different types of forming features, including internal forming features (30) (e.g., openings, holes, slits, slots, etc.) located within the interior of the patch and external forming features (32) (e.g., projections, fingers, recesses, waveforms, etc.) located along the perimeter of the patch.
Abstract:
A panel assembly (10) for use in any number of different applications, including a variety of vehicle applications, that reduces noise or vibrations, provides thermal insulation, and/or improves structural integrity. According to an exemplary embodiment, the panel assembly (10) includes a main panel (12) made from a metal, one or more sound damping patches (14, 16) also made from a metal, and an adhesive layer (18) that joins the patches (14, 16) to the main panel (12) in a constrained layer construction. The sound damping patches (14, 16) may include one or more forming features (30, 32), which are designed to improve the formability of the panel assembly (10) without significantly impairing its sound damping characteristics. There are different types of forming features, including internal forming features (30) (e.g., openings, holes, slits, slots, etc.) located within the interior of the patch and external forming features (32) (e.g., projections, fingers, recesses, waveforms, etc.) located along the perimeter of the patch.
Abstract:
A method of producing a composite component (10) that includes both a structural insert (12) and a plastic casing (14). According to an exemplary embodiment, the method uses a closed- loop control system and includes the following steps: evaluating the structural insert (12) for various attributes, placing the structural insert (12) in a mold cavity (62), adjusting the position and/or orientation of the structural insert (12) with respect to the mold cavity (62) based on, among other things, the evaluated attributes, and injecting molten material into the mold cavity (62) so that it at least partially surrounds the structural insert (12).
Abstract:
A method of producing a composite component (10) that includes both a structural insert (12) and a plastic casing (14). According to an exemplary embodiment, the method uses a closed- loop control system and includes the following steps: evaluating the structural insert (12) for various attributes, placing the structural insert (12) in a mold cavity (62), adjusting the position and/or orientation of the structural insert (12) with respect to the mold cavity (62) based on, among other things, the evaluated attributes, and injecting molten material into the mold cavity (62) so that it at least partially surrounds the structural insert (12).
Abstract:
A metal framing member (12) for use in a wide variety of applications including interior and exterior walls, structural insulated panels (SIPs), as well as floors, ceilings and roofs of residential and commercial buildings, to name but a few. The metal framing member generally includes first and second metal components (20, 22), where each of the metal components is a separate piece and includes an elongated support (30) with a series of fingers (34) extending therefrom. The two metal components are attached together near tips (52) of the fingers so that an alternating sequence of fingers and spaces (34, 36) is formed in an intermediate area between the two supports. This sequence can result in weight, material and cost savings, reduced thermal and acoustic conductivity across the metal framing member, and trade-ready holes for passing through items such as wires, pipes, etc.
Abstract:
A metal panel assembly (10, 110) that may be used in a number of different applications, particularly those that are concerned with improved stiffness and/or reduced vibration and noise. According to an exemplary embodiment, the metal panel assembly has a multi-layer or sandwich construction and includes a metal body layer (12, 112), a sound damping adhesive layer (14, 114), and a metal outer layer (16, 116). The outer layer is bonded to the body layer via the adhesive layer and improves the stiffness and/or reduces vibrations in the metal panel assembly. The outer layer may include a number of contact sections (42, 142) that confront the body layer through the adhesive layer, as well as a number of raised sections (44, 144) that are spaced from the body layer and increase or otherwise improve the stiffness of the metal panel assembly. In one embodiment, the raised sections (44) resemble channels and are generally arranged in a column-like pattern; in another embodiment, the raised sections (144) resemble ribs and are generally arranged in a grid-like pattern.
Abstract:
An apparatus, system and method for manufacturing metal parts, where input material is received from several material sources, multiple metal parts are produced at the same time, and the multiple metal parts may be provided to a downstream operation for subsequent processing. According to an exemplary embodiment, unwinding apparatuses (12, 14, 16) unwind metal coils (36, 38, 40) and provide three separate metal strips (30, 32, 34) to coil-fed metal forming press (18). The coil-fed metal forming press (18) then creates three separate blanks or metal parts (48) at the same time. Next, a part transfer apparatus (20) retrieves the three metal parts (48) from an output side of coil-fed metal forming press (18), and presents them to part assembly apparatus (22), which may include a laser welder or other piece of equipment. Once the metal parts (48) are properly positioned, part assembly apparatus (22) can create a metal part assembly (50) from the three individual blanks.
Abstract:
A metal forming process and welded coil assembly (100, 130, 160) that may be used to form complex metal components in a manner that is efficient, reduces scrap material, and maintains the structural integrity of the components. Generally, a number of individual metal blanks (102, 132, 162) are welded to one or more sheet metal coils (104, 106, 134, 164, 166) in order to produce a welded coil assembly. The metal blanks may be welded along the length of the inner sides of two sheet metal coils, or the metal blanks may be welded along the length of the outer sides of a single sheet metal coil, to cite a couple of possibilities. The welded coil assembly can then be fed through a progressive stamping apparatus (180) or other machine to create a complex metal part (188, 190, 198, 200).
Abstract:
A sound damping material (16) for use in a sound damping laminate (10) having one or more rigid layers (12, 14), such as those used in the automotive industry. The sound damping material (16) is preferably a viscoelastic material that damps or otherwise inhibits the transmission of vibrational or acoustical energy through laminate (10), and also acts as an adhesive for bonding the rigid layers (12, 14) together. In its cured form, sound damping material layer (16) preferably includes an acrylate-based polymer matrix (20), and one or more of the following components: a precipitated phase (22), a viscous phase (24), and miscellaneous constituents (26). The acrylate-based polymer matrix (20) is the reaction product of at least one acrylate-based monomer, such as isobornyl acrylate.