WO2026021914A1 - Élément de barrière et système de blocage d'un élément de structure - Google Patents

Élément de barrière et système de blocage d'un élément de structure

Info

Publication number
WO2026021914A1
WO2026021914A1 PCT/EP2025/070042 EP2025070042W WO2026021914A1 WO 2026021914 A1 WO2026021914 A1 WO 2026021914A1 EP 2025070042 W EP2025070042 W EP 2025070042W WO 2026021914 A1 WO2026021914 A1 WO 2026021914A1
Authority
WO
WIPO (PCT)
Prior art keywords
cavity
expandable material
expandable
barrier element
opening
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/EP2025/070042
Other languages
English (en)
Inventor
Henrik Lindgren
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sika Technology AG
Original Assignee
Sika Technology AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sika Technology AG filed Critical Sika Technology AG
Publication of WO2026021914A1 publication Critical patent/WO2026021914A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/001—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material
    • B62D29/002—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material a foamable synthetic material or metal being added in situ
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/18—Filling preformed cavities

Definitions

  • the invention relates to barrier element for blocking a cavity at least partially.
  • PUR-foam that is injected after the E-coat and paint ovens.
  • the foam is intended to completely fill a specific area and is either acoustic foams with high absorption or more rigid foam that stiffen the section.
  • Foam Blockers to stop or reduce the expansion.
  • These foam blockers can be a metal piece partly blocking the cavity or more commonly by a plastic carrier.
  • a common factor is that the cavities must not be 100% closed to fulfill their function, just sealing a major part of the cavity might be enough.
  • An expandable material that is extrudable and/or pumpable is used to at least partially block a cross-section of a cavity as a barrier element, in particular a cavity in a motor vehicle, upon expansion.
  • No additional carrier is used to block the cross section of the cavity.
  • the expandable material at least partially blocks the cross-section of the cavity in an expanded state. This enables a sustainable blocking of the cavity cross- section as the absence of a carrier means that no additional material is to be applied.
  • Carrier plates usually comprise a nylon material.
  • the term "pumpable" of the expandable material of the present application is understood such, that at ambient temperature (20°C) or elevated temperatures below the expansion initiation temperature the expandable material has a viscosity which is suitable for pumping and preferably has a paste-like viscosity.
  • the viscosity of the pumpable expandable material is usually in the range of 50 to 500 Pa s and preferably 100 to 300 Pa s, when measured by means of a rheometer with heatable plate (MCR 301, AntonPaar) (gap 1000 pm, measuring plate diameter: 25 mm (plate/plate), deformation 0.01-10 % at 5 Hz, temperature: 20°C).
  • MCR 301 heatable plate
  • AntonPaar heatable plate
  • the viscosity is lower than 50 Pa s, dripping can more easily occur, and the shape cannot sufficiently be maintained during processing. If on the other hand, the viscosity exceeds 500 Pa s, the workability of the material is greatly reduced.
  • pumpable does not refer to an inflatable material such as a balloon. Rather, the pumpable expandable material described herein may be a viscous, paste-like substance that can be applied through pumping equipment. Unlike an inflatable balloon that expands by filling with air or gas, this pumpable material may expand through chemical or physical processes when exposed to certain conditions, such as heat. The expansion of the material may result in a solid or semi-solid barrier element, rather than an air-filled structure. This distinction highlights the unique properties and applications of the pumpable expandable material in forming barrier elements within cavities.
  • EP3281970 discloses a pumpable expandable material based on combinations of a liquid epoxy resin and a polyvinyl chloride resin and/or an acrylic resin powder. These pumpable materials provide the advantage that they can be applied as needed using conventional injection equipment and can be expanded to provide foam with good physical strength, high expansion and good adhesion on oiled metal substrates.
  • the expandable material may alternatively be extrudable.
  • extrudable in the context of the present application refers to the ability of the expandable material to be forced through an opening or die to form a continuous shape or profile at temperatures below the expansion initiation temperature (ambient temperature (20°C) or elevated temperatures).
  • the extrudable expandable material may have a consistency that allows it to maintain its shape after extrusion while remaining sufficiently flowable to be processed through extrusion equipment.
  • the extrudable expandable material may have a viscosity that is suitable for extrusion processes, typically in the range of 200 to 800 Pa-s, and preferably 300 to 600 Pa-s, when measured by means of a rheometer with heatable plate (MCR 301, AntonPaar) under the same conditions as described for pumpable materials.
  • MCR 301 heatable plate
  • the viscosity is lower than 200 Pa-s for extrusion applications, the material may not maintain sufficient structural integrity during the extrusion process. If the viscosity exceeds 800 Pa-s, the material may become too stiff for efficient extrusion through standard equipment.
  • the extrudable expandable material may be applied using conventional extrusion equipment, such as pneumatic or electric extrusion guns, cartridge-based dispensing systems, or automated extrusion robots. This application method may provide advantages in terms of precise placement control, consistent bead dimensions, and the ability to create complex geometric patterns within the cavity.
  • the extruded material may form continuous or discontinuous beads, depending on the application requirements and the desired blocking characteristics of the barrier element.
  • the extrudable material may exhibit similar expansion characteristics to the pumpable variant, achieving expansion rates of at least 200%, preferably at least 500%, when subjected to appropriate activation conditions such as elevated temperatures.
  • the expanded extrudable material may provide equivalent or superior blocking performance compared to pumpable alternatives, while offering enhanced control over the initial placement geometry and distribution within the cavity.
  • the expandable material may have specific contact area arrangements that enhance its blocking performance.
  • the expandable material may comprise a first contact area and a second contact area, wherein the first contact area is arranged to contact the cavity wall while the second contact area is positioned opposite to the first contact area and does not contact the cavity wall.
  • This asymmetric contact arrangement may allow for efficient material usage while maintaining effective blocking performance.
  • the distance between the second contact area and the cavity wall may be maintained at 2 mm to 6 mm, providing optimal expansion space and blocking characteristics.
  • the cavity is arranged in a structural element.
  • the expandable material may be applied using robotic application systems.
  • Robotic application may provide enhanced precision in material placement, consistent bead formation, and improved repeatability compared to manual application methods.
  • the robotic system may be programmed to apply the expandable material in specific patterns, including non-continuous arrangements with predetermined gaps between beads. This automated approach may be particularly advantageous in automotive manufacturing environments where high precision and consistency are required.
  • the cavity is substantially blocked before filling the cavity with a curable material, in particular a curable reinforcing and/or acoustic material.
  • the curable material can be a PU (Polyurethan) material to reinforce or acoustically improve the cavity after curing.
  • the curable material can cure at room temperature through a chemical reaction without significant thermal activation.
  • the expanded material is used to block the spread of the curable material. This enables a precise and flexible positioning of the curable material in the cavity.
  • the expandable material may be configured to achieve enhanced expansion rates of at least 500%, or in some cases at least 800%, when subjected to appropriate activation conditions. These higher expansion rates may provide superior blocking performance and may enable the use of smaller initial material volumes while achieving effective cavity blocking. The enhanced expansion may be particularly beneficial in applications where space constraints limit the initial material placement volume.
  • the positioning of expandable material in the cavity is adjusted according to the needs of the assembly space in the cavity. This means that according to required reinforcement and/or acoustic properties, the position of the expandable material and therefore the barrier element in the cavity can be adjusted without additional construction effort, as no carrier has to be produced and transported. No carrier has to be adapted to the shape of the assembly space.
  • the cavity does not need to be provided with fastening means to fasten a carrier.
  • the cavity In the expandable state the cavity is in fluid communication. In other words, in the expandable state the cavity is not substantially blocked. This means that in the expandable state, there is a significant opening in the cavity not filled, neither with expandable material nor with a carrier.
  • the positioning of openings in the structural element may be specifically configured to optimize material application and cavity filling.
  • the first opening, through which the expandable material is applied, and the second opening, through which the curable material is introduced, may be positioned at different locations on the structural element. This differential positioning may enable better control over material flow and distribution within the cavity.
  • the openings may be arranged in different walls of the cavity to facilitate optimal access and material placement.
  • a further aspect of the invention concerns the barrier element itself, in particular a barrier element for at least partially block a cross-section of a cavity, in particular in a structural element, in particular in a vehicle body.
  • the barrier element comprises an expandable material, in particular a pumpable and expandable material.
  • the barrier element is equipped to block a cavity.
  • the barrier element is equipped to block a cavity against substantial inflow of a curable material in an expanded state.
  • the barrier element is free of a carrier element. In an expandable state the barrier element, in particular the expandable material, is pumpable. This leads to a very sustainable barrier element, as no additional carrier is needed in the assembly space.
  • the expandable material may comprise specific material compositions that enhance its performance characteristics.
  • the expandable material may comprise a combination of a liquid epoxy resin and at least one of a polyvinyl chloride resin and an acrylic resin powder. This combination may provide optimal viscosity characteristics for both pumpable and extrudable applications while maintaining excellent expansion properties and adhesion to cavity surfaces.
  • the material composition may be tailored to achieve specific viscosity ranges suitable for different application methods.
  • the cavity resp. the structural element comprises a first and a second contact area.
  • the first contact area is arranged opposite to the second contact area.
  • the expandable material contacts the cavity resp. the structural element at a first contact area and a second contact area free of contact with the expandable material. Meaning, that the second contact area of the cavity resp. the structural element is free of any contact with the expandable material and does not contact resp. touch it.
  • the expandable material is arranged in the cavity such, that there is a distance between the second contact area of the cavity resp. the structural element and the expandable material.
  • the expandable material in the expandable state does not touch a cavity wall in a circumferential manner. This means that the expandable material does not contact the entire circumference of the inner wall of the cavity. In other words, a portion of the cavity wall opposite to the expandable material remains free of contact with the expandable material. This configuration enables a further reduction in material usage, resulting in a more sustainable and cost-effective barrier element while maintaining effective blocking performance.
  • the expandable material is applied to the inner wall of the cavity in a non- continuous manner. This leads to a reduced material usage.
  • the gap between beads of pumped, expandable material is free of additional material. This enables a reliable and costefficient blocking of the cavity cross-section.
  • the expandable material is pumpable at a temperature of less than 80°C and/or wherein the expandable material is expanded at a temperature of more than 100°C. This enables a subsequent pumping and controlled expansion at different temperatures.
  • the barrier element is equipped to reduce the airborne noise in the cavity by at least 20%, in particular at least 35%, in particular at least 45%, in particular compared to a barrier element made of steel or nylon, similar to the one shown in Fig. 6a.
  • the barrier element can by equipped to the structure born noise in the cavity by 15 %, in particular 20%, in particular at least 35%, in particular compared to a barrier element made of steel or nylon, similarto the one shown in Fig. 7a.
  • the noise reduction forthe airborne noise can be achieved at the side of the cavity facing the barrier element.
  • the noise reduction of the structure borne noise can be achieved on the side of the cavity facing the curable or cured material.
  • the barrier element may be configured to achieve enhanced noise reduction performance.
  • the barrier element may be equipped to reduce airborne noise in the cavity by at least 45%, and in some cases up to 60% or more, compared to conventional barrier elements made of steel or nylon. Additionally, the barrier element may reduce structure-borne noise by at least 35%, and in some cases up to 50% or more. This enhanced acoustic performance may be attributed to the specific material properties and expansion characteristics of the expandable material, which may provide superior damping and absorption compared to rigid carrier-based systems.
  • the expanded barrier element may be configured to block a substantial portion of the cavity cross-section, typically at least 90% of the cross-sectional area. This high blocking percentage may ensure effective containment of the curable material while maintaining the desired cavity reinforcement characteristics. The blocking percentage may be achieved through appropriate selection of expandable material volume, expansion rate, and placement pattern within the cavity.
  • Another aspect of the invention is focused on a method to reinforce a cavity.
  • the method to reinforce and/or damp a cavity comprises the steps of: a. applying an expandable material in the cavity in the cavity, in particular to the crosssection of the cavity; b. expanding the expandable material in the cavity as a barrier element and thereby blocking the cavity at least partially in particular at least 90% of the cavity cross-section, by the expanded material to build a barrier element, in particular a barrier element as described in the present text; c. filling the cavity with a curable material, in particular a curable reinforcing material, up to the barrier element in the expanded state, and curing the curable material, wherein the cavity is free of any carrier supporting the expandable material. In particular the cavity is free of any carrier at the cross-section of the cavity.
  • the expandable material is pumpable and/or extrudable, and wherein the pumpable expandable material having a viscosity in the range of 50 to 500 Pa-s when measured by means of a rheometer with heatable plate at 20°C.
  • the method may include specific application parameters that enhance the effectiveness of the barrier element formation.
  • the expandable material may be applied at controlled viscosity ranges, with pumpable materials having viscosity in the range of 50 to 500 Pa-s , in particular 100 to 300 Pa-s, and extrudable materials having viscosity in the range of 300 to 600 Pa-s when measured at 20°C.
  • the application may be performed in a non- continuous manner, forming discrete beads with predetermined gaps between them, which may optimize material usage while maintaining effective blocking performance.
  • the expandable material is applied by pumping or extruding the expandable material, in particular in form of one or more beads, into the cavity.
  • This application method provides precise control over material placement and distribution within the cavity structure.
  • the pumped or extruded, in particular beaded, application pattern allows for optimal expansion characteristics while minimizing material usage.
  • the expandable material When applied as discrete beads, the expandable material can maintain its position during the pre-expansion phase and subsequently expand in a controlled manner to effectively block the cavity cross-section.
  • the bead formation may be continuous or discontinuous depending on the specific blocking requirements and cavity geometry.
  • the diameter and length of the beads can be adjusted according to the cavity dimensions and the desired blocking percentage.
  • the cavity comprises at least a first opening and a second opening.
  • the openings are connecting the inner space (also called inside) of the cavity with the space surrounding the cavity (also called outside).
  • the expandable material is applied into the cavity through the first opening and the curable material, in particular a curable reinforcing and/or acoustic material, is filled into the cavity through the second opening. This makes it possible that the expandable material and therefore the barrier element can be applied next to the curable material, enabling the blocking of the cavity and a stopping of the curable material.
  • the first opening is at a different position than the second opening.
  • At least one of the openings is arranged in a wall of cavity.
  • the wall is delimiting/surrounding the cavity.
  • the first opening is at a different position than the second opening.
  • the first opening and/or the second opening has a circular shape. This supports the stress resistance of the cavity.
  • the openings in the structural element may have specific geometric configurations that facilitate optimal material application.
  • the first opening and the second opening may each have a circular shape, which may provide structural integrity and facilitate sealing after material application.
  • the circular configuration may also enable the use of standard application equipment and may reduce stress concentrations in the structural element.
  • the openings may be positioned in different walls of the cavity to enable independent control of expandable material and curable material introduction.
  • the expandable material comprises a first expandable material and a second expandable material; wherein the method comprises the step of:
  • first expandable material and the second expandable material are different from each other. Different meaning that the expandable materials comprise a different composition.
  • first expandable material and the second expandable material are essentially identical. Identical means that the composition of the first expandable material and the second expandable material are essentially the same. In other words, the mechanical and chemical properties of the first expandable material and the second expandable material are essentially the same.
  • Another aspect of the invention concerns a system for blocking a cavity.
  • the system for blocking a structural element in a motor vehicle comprising a structural element wherein the structural element forms the cavity.
  • the system further comprising an expandable material which is arranged on the structural element by pumping.
  • the expandable material is formed and arranged such that the expandable material at least partially blocks the cross section of the cavity in an expanded state and forms a barrier element in the expanded state, in particular a barrier element as described in this text.
  • the system is free of a carrier. This makes it possible to sustainably and cost efficiently block the cavity.
  • the system may incorporate advanced application methods that enhance precision and consistency.
  • the expandable material may be applied using robotic systems that provide precise control over material placement, bead dimensions, and application patterns.
  • the robotic application may enable the formation of complex geometric arrangements within the cavity, including non-continuous patterns with specific gap dimensions between material beads. This automated approach may be particularly beneficial in high-volume manufacturing environments where consistency and repeatability are critical.
  • a structural element comprises a first component and a second component, wherein the components are joined together at a first joining point and at a second joining point.
  • the structural element forms the cavity.
  • the expandable material contacts the structural element at the first joining point and/or at the second joining point. This enables a simplified assembly of the system.
  • the expandable material has, in each case proceeding from the joining points, an extent along the second component of the structural element of at least 10 mm. This enables a reliable connection and sealing of the cavity.
  • the system may be configured with specific dimensional relationships that optimize blocking performance.
  • the distance between the expanded material and the structural element at non-contact areas may be maintained within a range of 2 mm to 6 mm, providing optimal expansion space while ensuring effective blocking.
  • the expandable material may be arranged to contact the structural element at specific contact areas while maintaining predetermined distances at opposite areas, creating an asymmetric contact pattern that may enhance both material efficiency and blocking effectiveness.
  • the second expandable material forms a continuous element between the joining points.
  • the structural element comprises at least a first opening and a second opening.
  • the openings are connecting the inside of the structural element with outside of the structural element.
  • the expandable material is applied into the structural element through the first opening.
  • the curable material in particular a curable reinforcing and/or acoustic material, is filled into the structural element through the second opening. This enables to provide a system with the expandable material arranged next to the curable material.
  • the first opening and/or the second opening have a circular shape. This increases the stress resistance of the system.
  • the expandable material is in an expandable state and is configured, and arranged, in such a way that, after the material has been expanded, the expanded material at least partially blocks/fills a cross section of the structural element.
  • a distance between the expanded material (expandable material in the expanded state) and the structural element is 2 mm to 6 mm.
  • the position of the barrier element 1 can be adjusted by repositioning an expandable material, that is pumpable and/or extrudable, in the cavity 30 and expand it. Accordingly, the position of the expanded barrier element 1 is adjusted influencing the stop of the curable material 40. This also enables the adjustment and optimization of the filling of the cavity 30 with the curable material 40 and leaving the critical area 19 free from curable material 40.
  • Figs. 4a & 4b show a sectional view of a structural element 3.
  • Fig. 4a depicts the expandable material 10 arranged in the cavity 30.
  • Fig.4b shows the expanded barrier element 1 with the cured material 41.
  • the expandable material 10 is arranged at a position opposite the first opening 31 in the structural element 3.
  • the barrier element 1 blocks the cross-section of the cavity 30 resp. the structural element 3.
  • the curable material 40 is injected into the cavity 30 through the second opening 32 and cures after injection in the cavity 30.
  • a significant part of the airborne noise is dissipated by either the expanded barrier element or the cured material 41, in particular after transmission from the expanded barrier element 1 to the cured material 41.
  • the barrier element 1 is equipped to reduce the airborne noise by at least 20%, in particular at least 35%, in the cavity 30.
  • NA(D) dissipated air borne noise by the barrier element in the expanded state

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Mechanical Engineering (AREA)
  • Body Structure For Vehicles (AREA)

Abstract

Selon l'invention, un matériau expansible qui peut être pompé et/ou extrudé, est utilisé pour bloquer au moins partiellement une section transversale d'une cavité en tant qu'élément barrière, notamment une cavité dans un véhicule à moteur, lors de l'expansion. Aucun support supplémentaire n'est utilisé pour bloquer la section de la cavité. Même en l'absence de support, le matériau expansible bloque au moins partiellement la section de la cavité dans un état expansé. Ceci permet un blocage durable de la section de cavité en l'absence de moyen porteur qu'aucun matériau supplémentaire ne doit être appliqué.
PCT/EP2025/070042 2024-07-22 2025-07-14 Élément de barrière et système de blocage d'un élément de structure Pending WO2026021914A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP24190151.1 2024-07-22
EP24190151 2024-07-22

Publications (1)

Publication Number Publication Date
WO2026021914A1 true WO2026021914A1 (fr) 2026-01-29

Family

ID=91961940

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2025/070042 Pending WO2026021914A1 (fr) 2024-07-22 2025-07-14 Élément de barrière et système de blocage d'un élément de structure

Country Status (1)

Country Link
WO (1) WO2026021914A1 (fr)

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7169344B2 (en) * 2002-04-26 2007-01-30 L&L Products, Inc. Method of reinforcing at least a portion of a structure
FR2884200B1 (fr) * 2005-04-06 2007-06-29 Cera Dispositif de remplissage d'un element creux comprenant des parois d'association audit element
US20080257491A1 (en) * 2002-04-30 2008-10-23 Zephyros, Inc. Reinforcement system utilizing a hollow carrier
EP3281970A1 (fr) 2016-08-08 2018-02-14 Sika Technology Ag Compositions de remplissage thermiquement expansibles et pompables
US20210163078A1 (en) * 2018-08-31 2021-06-03 Sika Technology Ag System for insulating a structural element
EP3978557A1 (fr) * 2020-09-30 2022-04-06 Sika Technology Ag Compositions de remplissage pompables et thermiquement expansibles à temps ouvert prolongé
WO2023205498A1 (fr) * 2022-04-22 2023-10-26 Zephyros, Inc. Renfort de structure léger

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7169344B2 (en) * 2002-04-26 2007-01-30 L&L Products, Inc. Method of reinforcing at least a portion of a structure
US20080257491A1 (en) * 2002-04-30 2008-10-23 Zephyros, Inc. Reinforcement system utilizing a hollow carrier
FR2884200B1 (fr) * 2005-04-06 2007-06-29 Cera Dispositif de remplissage d'un element creux comprenant des parois d'association audit element
EP3281970A1 (fr) 2016-08-08 2018-02-14 Sika Technology Ag Compositions de remplissage thermiquement expansibles et pompables
US20210163078A1 (en) * 2018-08-31 2021-06-03 Sika Technology Ag System for insulating a structural element
EP3978557A1 (fr) * 2020-09-30 2022-04-06 Sika Technology Ag Compositions de remplissage pompables et thermiquement expansibles à temps ouvert prolongé
WO2023205498A1 (fr) * 2022-04-22 2023-10-26 Zephyros, Inc. Renfort de structure léger

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