GB2460040A

GB2460040A - Fastening component with integral attachment

Info

Publication number: GB2460040A
Application number: GB0808638A
Authority: GB
Inventors: Fabien Escudier
Original assignee: Zephyros Inc
Current assignee: Zephyros Inc
Priority date: 2008-05-13
Filing date: 2008-05-13
Publication date: 2009-11-18
Also published as: GB0808638D0

Abstract

A first component 1 is provided with an integrally formed attachment means (2-6) lying in the plane of the component (fig. 1) which can be rotated out of the plane of the first component to an upstanding position (figs. 2, 3) to pass through an orifice in a second component to form the attachment.

Description

IMPROVEMENTS IN OR RELATING TO ATTACHMENTS

The present invention relates to improvements in or relating to means of attachment.

In particular the invention relates to fastening two components during manufacture such as in the manufacture of automobiles, aircraft, railroad vehicles, trucks and busses.

During such manufacture it is frequently required to fasten components such as for example the provision of acoustic baffles and sealants, structural reinforcements which can include a foamable adhesive material on a carrier to the basic structure of the vehicle which may be any structure of the vehicle such as a vehicle body in white, a vehicle seat sub structure, an air frame or other similar structures. In instances where the component comprises a foamable material attached to a carrier the invention may be used for the attachment of the foamable material to the carrier.

Means of attachment are known, for example clips may be integrally moulded with plastic components so that the component can be clipped into holes provided in the metal structure for receipt of the clip. This however involves a complex and expensive moulding technique and furthermore cannot be used in confined spaces.

Examples of attachment systems that are currently used for the attachment of automobile components such as acoustic baffles, sealants and structural reinforcement components may be found in European Patent 837252. In other systems materials required to form a particular function may be provided with an adhesive function and/or may be applied in place such as by extrusion in place.

Although these systems perform well they either require expensive moulding techniques or cannot be implemented in confined spaces. The present invention provides simple attachments that do not suffer from these problems.

The present invention provides a component for attachment provided with an integral means for attachment lying substantially in the plane of the component which can be rotated relative to the plane of the component to provide an attachment means standing proud from the plane of the component. * *S

35 In a further embodiment the invention provides an assembly comprising a first component attached to a second component wherein the attachment comprises an * * * *** * *** * ** ** * * * * * *I integral part of the first component which stands proud of the plane of the first component and is secured within an orifice provided in the second component.

In a further embodiment the invention provides a process for attaching a first component to a second component comprising providing a component which contains an integral means for attachment lying substantially in the plane of the component and which can be rotated relative to the plane of the component to provide attachment means standing proud from the plane of the component on the surface of a second component which is provided with one or more orifices for receipt of the attachment means comprising rotating the attachment means from the plane of the component to pass through the orifice to attach the first component to the second component.

The component of the present invention may be made of any material that has the flexibility to enable the attachment means to be rotated out of the plane of the component without breaking. The material is preferably a synthetic resin based material and is preferably a material that can be processed by calending, injection moulding, blow moulding or extrusion. In a preferred embodiment the material is foamable and is such that it can be foamed after it has been attached to the second component. In particular in automobile manufacture the material may be such that it is foamed at the temperatures experienced in the vehicle paint oven or e-coat oven.

The components will be made from a polymer formulation which is selected according to the use to which the component is to be put. For example the material may be soft and flexible if a sealing function is required. It may be soft and adapted to form an open cell foam if it is required to perform as an acoustic baffle.

Alternatively it may be a material that can be cured to provide a rigid, optionally foamed structure if a reinforcing function is required.

The compositions used to provide the components of this invention may contain one or more of the following ingredients i) epoxy resins; ii) polymers; * *. ii) blowing agent; * S * iv) filler; v) flow control materials and * *.* vi) nano particles ** S S. S. * * S * vii) epoxy/elastomer adducts viii) phenoxy resins ix) core/shell polymers.

Epoxy Resin The preferred formulations used in the present invention include epoxy resins. Epoxy resin is used herein to mean any of the conventional dimeric, oligomeric or polymeric epoxy materials containing at least one epoxy functional group. The term epoxy resin can be used to denote one epoxy resin or a combination of multiple epoxy resins. The polymer-based materials may be epoxy-containing materials having one or more oxirane rings polymerizable by a ring opening reaction. In preferred embodiments, the material includes between about 2% and 75% by weight epoxy resin, more preferably between about 4% and 60% by weight epoxy resin and even more preferably between about 25% and 50% by weight epoxy resin. Of course, amounts of epoxy resin may be greater or lower depending upon the intended application of the material.

The epoxy may be aliphatic, cycloaliphatic, aromatic or the like. The epoxy may be supplied as a solid (e.g., as pellets, chunks, pieces or the like) or a liquid (e.g., an epoxy resin) although liquid resins are preferred to enhance processability of the formulation. As used herein, unless otherwise stated, a resin is a solid resin if it is solid at a temperature of 23°C and is a liquid resin if it is a liquid at 23°C. The epoxy may include an ethylene copolymer or terpolymer. As a copolymer or terpolymer, the polymer is composed of two or three different monomers, i.e., small molecules with high chemical reactivity that are capable of linking up with similar molecules.

An epoxy resin may be added to the material to increase the adhesion, flow properties or both of the material. One exemplary epoxy resin may be a phenolic resin, which may be a novolac type or other type resin. Other preferred epoxy containing materials may include a bisphenol-A epichlorohydrin ether polymer, or a bisphenol-A epoxy resin which may be modified with butadiene or another polymeric additive or bisphenol-F-type epoxy resins. Moreover, various mixtures of several different epoxy resins may be employed as well. Examples of suitable epoxy resins u::::' are sold under the tradename Araldite GY 282, GY 281 and GY 285 supplied by Huntsman. * I **I

* *** Polymer or Copolymer

I I. S. * * .

S S.

Depending upon the use to which the material is to be put, it may comprise or include one or more polymers or copolymers, which can include a variety of different polymers, such as thermoplastics, elastomers, plastomers and combinations thereof or the like. For example, and without limitation, polymers that might be appropriately incorporated into the structural adhesive include halogenated polymers, polycarbonates, polyketones, urethanes, polyesters, silanes, sulfones, allyls, olefins, styrenes, acrylates, methacrylates, epoxies, silicones, phenolics, rubbers, polyphenylene oxides, terphthalates, acetates (e.g., EVA), acrylates, methacrylates (e.g., ethylene methyl acrylate polymer) or mixtures thereof. Other potential polymeric materials may be or may include, without limitation, polyolefin (e.g., polyethylene, polypropylene) polystyrene, polyacrylate, poly(ethylene oxide), poly(ethyleneimine), polyester, polyurethane, polysiloxane, polyether, polyphosphazine, polyamide, polyimide, polyisobutylene, polyacrylonitrile, poly(vinyl chloride), poly(methyl methacrylate), poly(vinyl acetate), poly(vinylidene chloride), polytetrafluoroethylene, polyisoprene, polyacrylamide, polyacrylic acid, polymethacrylate.

When used, these polymers can comprise a small portion or a more substantial portion of the material. When used, the one or more additional polymers preferably comprises about 0.1% to about 50%, more preferably about 1% to about 20% and even more preferably about 2% to about 10% by weight of the material.

In certain embodiments, it may be desirable to include one or more thermoplastic polyethers and/or thermoplastic epoxy resins in the material. When included, the one or more thermoplastic polyethers preferably comprise between about 1% and about 90% by weight of the material, more preferably between about 3% and about 60% by weight of the material and even more preferably between about 4% and about 25% by weight of the material. As with the other materials, however, more or less thermoplastic polyether may be employed depending upon the intended use of the material. * **

The thermoplastic polyethers typically include pendant hydroxyl moieties. The thermoplastic polyethers may also include aromatic ether/amine repeating units in their backbones. The thermoplastic polyethers of the present invention preferably * * 35 have a melt index between about 5 and about 100, more preferab!y between about and about 75 and even more preferably between about 40 and about 60 grams per 10 minutes for samples weighing 2.16 Kg at a temperature of about 190°C. Of * * I * * SI * * S S. *. 4 course, the thermoplastic polyethers may have higher or lower melt indices depending upon their intended application. Preferred thermoplastic polyethers include, without limitation, polyetheramines, poly(amino ethers), copolymers of monoethanolamine and diglycidyl ether, combinations thereof or the like.

Preferably, the thermoplastic polyethers are formed by reacting an amine with an average functionality of 2 or less (e.g., a difunctional amine) with a glycidyl ether (e.g., a diglycidyl ether). As used herein, the term difunctional amine refers to an amine with an average of two reactive groups (e.g., reactive hydrogens).

The thermoplastic polyether may be formed by reacting a primary amine, a bis(secondary) diamine, a cyclic diamine, a combination thereof or the like (e.g., monoethanolamine) with a diglycidyl ether or by reacting an amine with an epoxy-functionalized poly(alkylene oxide) to form a poly(amino ether). Alternatively, the thermoplastic polyether may be prepared by reacting a difunctional amine with a diglycidyl ether or diepoxy-functionalized poly(alkylene oxide) under conditions sufficient to cause the amine moieties to react with the epoxy moieties to form a polymer backbone having amine linkages, ether linkages and pendant hydroxyl moieties. Optionally, the polymer may be treated with a monofunctional nucleophile which may or may not be a primary or secondary amine.

Additionally, it is contemplated that amines (e.g., cyclic amines) with one reactive group (e.g., one reactive hydrogen) may be employed for forming the thermoplastic polyether. Advantageously, such amines may assist in controlling the molecular weight of the thermoplastic ether formed.

Examples of preferred thermoplastic polyethers and their methods of formation are disclosed in United States Patents 5,275,853; 5,464924 and 5,962,093.

Advantageously, the thermoplastic polyethers can provide the material with various desirable characteristics such as desirable physical and chemical properties for a wide variety of applications as is further described herein. * * * * * **

* The formulation may include one or more ethylene polymers or copolymers such as ethylene acrylates, ethylene acetates or the like. Ethylene methacrylate and ethylene vinyl acetate are two preferred ethylene copolymers. ** * * * * **

** *.* 5 It may also be desirable to include a reactive polyethylene resin that is modified with one or more reactive groups such as glycidyl methacrylate or maleic anhydride.

Examples of such polyethylene resins are sold under the tradename LOTADER� (e.g., LOTADER AX 8900) and are commercially available from Arkema Group.

The material may be expandable or non expandable. If the material is expandable one or more blowing agents may be added to the material for producing inert gasses that form, as desired, an open and/or closed cellular structure within the material. In this manner, it may be possible to lower the density of articles fabricated from the material. In addition, the material expansion can help to improve sealing capability, acoustic damping and adhesion to bonding substrate.

The blowing agent may include one or more nitrogen containing groups such as amides, amines and the like. Examples of suitable blowing agents include azodicarbonamide, dinitrosopentamethylenetetramine, azodicarbonamide, dinitrosopentamethylenetetramine, 4,41-oxy-bis-(benzenesulphonylhydrazide), trihydrazinotriazine and N, N-dimethyl-N, N-dinitrosoterephthalamide. An accelerator for the blowing agents may also be provided in the material. Various accelerators may be used to increase the rate at which the blowing agents form inert gasses.

One preferred blowing agent accelerator is a metal salt, or is an oxide, e.g. a metal oxide, such as zinc oxide. Other preferred accelerators include modified and unmodified thiazoles or imidazoles.

Amounts of blowing agents and blowing agent accelerators can vary widely within the material depending upon the type of cellular structure desired, the desired amount of expansion of the material, the desired rate of expansion and the like. Exemplary ranges for the amounts of blowing agents and blowing agent accelerators in the material range from about 0.001% by weight to about 5% by weight and are preferably in the material in fractions of weight percentages.

Filler * ** **.. The material may also include one or more fillers, including but not limited to particulate materials (e.g., powder), beads, microspheres such as Zeospheres available from Zeelan Industries, or the like. Preferably the filler includes a material * ** that is generally non-reactive with the other components present in the material, While the fillers may generally be present within the material to take up space at a ** * * * * S *S * * S * * ** 6 relatively low weight, it is contemplated that the fillers may also impart properties such as strength and impact resistance to the material.

Examples of fillers include silica, diatomaceous earth, glass, clay (e.g., including nanoclay), talc, pigments, colorants, glass beads or bubbles, glass, carbon or ceramic fibers, nylon or polyamide fibers (e.g., Kevlar), antioxidants, and the like.

Such fillers, particularly clays, can assist the material in leveling itself during flow of the material. The clays that may be used as fillers may include clays from the kaolinite, illite, chloritem, smecitite or sepiolite groups, which may be calcined.

Examples of suitable fillers include, without limitation, talc, vermiculite, pyrophyllite, sauconite, saponite, nontronite, montmorillonite or mixtures thereof. The clays may also include minor amounts of other ingredients such as carbonates, feldspars, micas and quartz. The fillers may also include ammonium chlorides such as dimethyl ammonium chloride and dimethyl benzyl ammonium chloride. Titanium dioxide might also be employed.

In one preferred embodiment, one or more mineral or stone type fillers such as calcium carbonate, sodium carbonate or the like may be used as fillers. In another preferred embodiment, silicate minerals such as mica may be used as fillers.

When employed, the fillers in the material can range from 10 % or less to 90 % or greater by weight of the material, but more typical from about 20 to 55 % by weight of the material. According to some embodiments, the material may include from about 0 % to about 3 % by weight, and more preferably slightly less that I % by weight clays or similar fillers. Powdered (e.g. about 0.01 to about 50, and more preferably about 1 to 25 micron mean particle diameter) mineral type filler can comprise between about 5 % and 70 % by weight, more preferably about 10 % to about 50% by weight.

An epoxy elastomer adduct which imports flexibility to the material and the ability to initiate plastic deformation may be included. Various epoxy/elastomer adducts may * be employed in the present invention. The epoxy/elastomer hybrid or adduct may be ** included in an amount of up to about 50% by weight of the material. The epoxy elastomer adduct is approximately at least 5%, more typically at least 7% and even more typically at least 10% by weight of the mater and more preferab!y about 5% to 20% by weight of the adduct based on the material. The elastomer-containing adduct may be a combination of two or more particular adducts and the adducts may be solid adducts, liquid adducts or semi-solids at a temperature of 23°C or may also be combinations thereof. In one preferred embodiment, the adduct is composed of substantially entirely (i.e., at least 70%, 80%, 90% or more) of one or more adducts that are solid at a temperature of 23°C.

The adduct itself generally includes about 1:5 to 5:1 parts of epoxy to elastomer, and more preferably about 1:3 to 3:1 parts of epoxy to elastomer. More typically, the adduct includes at least about 10%, more typically at least about 20% and even more typically at least about 40% elastomer and also typically includes not greater than about 60%, although higher or lower percentages are possible. The elastomer compound suitable for the adduct may be a thermosetting elastomer, although not required. Exemplary elastomers include, without limitation, natural rubber, styrene-butadiene rubber, polyisoprene, polyisobutylene, polybutadiene, isoprene-butadiene copolymer, neoprene, nitrile rubber (e.g., a butyl nitrile, such as carboxy-terminated butyl nitrile), butyl rubber, polysulfide elastomer, acrylic elastomer, acrylonitrile elastomers, silicone rubber, polysiloxanes, polyester rubber, diisocyanate-linked condensation elastomer, EPDM (ethylene-propylene diene rubbers), chlorosulphonated polyethylene, fluorinated hydrocarbons and the like. In one embodiment, recycled tire rubber is employed. Examples of additional or alternative epoxy/elastomer or other adducts suitable for use in the present invention are disclosed in United States Patent Publication 2004/0204551.

The elastomer-containing adduct is included to modify structural properties of the material such as strength, toughness, stiffness, flexural modulus, or the like.

Additionally, the elastomer-containing adduct may be selected to render the material more compatible with coatings such as water-borne paint or primer system or other conventional coatings.

Phenoxy resins may also be included, phenoxy resins are high molecular weight thermoplastic condensation products of bisphenol A and epichloro-hydrin and their derivatives. Typically the phenoxy resins that are employed are of the basic formula * * . * * .*

S S... *. OH

t.:. -Cl-IS HO CH3 -CH2 -CH -CH2 -oj_ *. S.: 8 where n is typically from 30 to 100 preferably from 50 to 90. Modified phenoxy resins may also be used. Examples of phenoxy resins that may be used are the products marketed by Inchem Corp. Examples of suitable materials are the PKHB, PKHC, PKHH, PKHJ, PKHP pellets and powder. Alternatively phenoxy/polyester hybrids and epoxy/phenoxy hybrids may be used. In order to enhance the production of the material it is preferred that the phenoxy resin be supplied to the other components as a solution. While any solvent may be used it is particularly preferred to use a liquid epoxy resin as the solvent as this can also contribute to the adhesive properties upon activation.

Core/shell polymers may also be included, as used herein, the term core/shell polymer denotes a polymeric material wherein a substantial portion (e.g., greater than 30%, 50%, 70% or more by weight) thereof is comprised of a first polymeric material (i.e., the first or core material) that is substantially entirely encapsulated by a second polymeric material (i.e., the second or shell material). The first and second polymeric materials, as used herein, can be comprised of one, two, three or more polymers that are combined and/or reacted together (e.g., sequentially polymerized) or may be part of separate or same core/shell systems. The core/shell polymer should be compatible with the formulation and preferably has a ductile core and a rigid shell which is compatible with the other components of the structural adhesive formulation.

The first and second polymeric materials of the core/shell polymer can include elastomers, polymers, thermoplastics, copolymers, other components, combinations thereof or the like. In preferred embodiments, the first polymeric material, the second polymeric material or both include or are substantially entirely composed of (e.g., at least 70%, 80%, 90% or more by weight) one or more thermoplastics. Exemplary thermoplastics include, without limitation, styrenics, acrylonitriles, acrylates, acetates, polyamides, polyethylenes or the like. *

Preferred core/shell polymers are formed by emulsion polymerization followed by coagulation or spray drying. It is also preferred for the core/shell polymer to be formed of or at least include a core-shell graft co-polymer. The first or core polymeric * 35 material of the graft copolymer preferabiy has a glass transition temperature substantially below (i.e., at least 10, 20, 40 or more degrees centigrade) the glass transition temperature of the second or shell polymeric material. Moreover, it may be * . * * ** *. **. 9 desirable for the glass transition temperature of the first or core polymeric material to be below 23°C while the glass temperature of the second or shell polymeric material to be above 23°C, although not required.

Examples of useful core-shell graft copolymers are those where hard containing compounds, such as styrene, acrylonitrile or methyl methacrylate, are grafted onto a core made from polymers of soft or elastomeric compounds such as butadiene or butyl acrylate. Untied States Patent 3,985,703, describes useful core-shell polymers, the cores of which are made from butyl acrylate but can be based on ethyl isobutyl, 2-ethylhexyl or other alkyl acrylates or mixtures thereof. The core polymer, may also include other copolymerizable containing compounds, such as styrene, vinyl acetate, methyl methacrylate, butadiene, isoprene, or the like. The core polymer material may also include a cross linking monomer having two or more nonconjugated double bonds of approximately equal reactivity such as ethylene glycol diacrylate, butylene glycol dimethacrylate, and the like. The core polymer material may also include a graft linking monomer having two or more nonconjugated double bonds of unequal reactivity such as, for example, diallyl maleate and allyl methacrylate.

The shell portion is preferably polymerized from methyl acrylates such as methyl methacrylate and optionally other alkyl acrylates and methacrylates, such as ethyl, butyl, or mixtures thereof acrylates or methacrylates as these materials are compatible with the phenoxy resin and any epoxy resins that are used in the formulation. Up to 40 percent by weight or more of the shell monomers may be styrene, vinyl acetate, vinyl chloride, and the like. Additional core-shell graft copolymers useful in embodiments of the present invention are described in United States Patent 3,984,497; 4,096,202; 4,034,013; 3,944,631; 4,306,040; 4,495,324; 4,304,709; and 4,536,436. Examples of core-shell graft copolymers include, but are not limited to, "MBS" (methacrylate-butadiene-styrene) polymers, which are made by polymerizing methyl methacrylate in the presence of polybutadiene or a polybutadiene copolymer rubber. The MBS graft copolymer resin generally has a styrene butadiene rubber core and a shell of acrylic polymer or copolymer. * **

** ,.e Examples of other useful core-shell graft copolymer resins include, ABS (acrylonitrile- * butadiene-styrene), MABS (methacrylate-acrylonitrile-butadiene-styrene), ASA (acrylate-styrene-acrylonitrile), all acrylics, SA EPDM (styrene-acrylonitrile grafted * *S_ : * 35 onto elastomeric backbones of ethyene-propylenc diene monomer), MAS (methacrylic-acrylic rubber styrene), and the like and mixtures thereof. *. ** * * * * S *S *

S S

*S 55 10 Examples of useful core/shell polymers include, but are not limited to those sold under the tradename, PARALOID, commercially available from Rohm & Haas Co. One particularly preferred grade of PARALOID impact modifier has a polymethyl methacrylate shell and an MBS core modifier and is sold under the designation EXL- 2650; the product E-950 solid by Akema may also be used with equal effectiveness.

We prefer to use from 5% to 30% of the core shell polymer particularly when the adhesive is to be applied as a paste as higher amounts can lead to an undesirably high viscosity.

Where the material is to be cured to provide a rigid structure one or more curing agents are included in the material of this invention. Optionally curing agent accelerators may also be included. The amounts of curing agents and curing agent accelerators used can vary widely depending upon the type of structure desired, the desired structural properties of the material and the like and in the embodiment when the material is expandable the desired amount of expansion of the material and the desired rate of expansion. Exemplary ranges for the curing agents or curing agent accelerators present in the material range from about 0.001% by weight to about 7% by weight.

Preferably, the curing agents assist the material in curing by crosslinking of the polymers, phenoxy epoxy resins and epoxy resin that may be present. It is also preferable for the curing agents to assist in thermosetting the material. Useful classes of curing agents are materials selected from aliphatic or aromatic amines or their respective adducts, amidoamines, polyamides, cycloaliphatic amines, anhydrides, polycarboxylic polyesters, isocyanates, phenol-based resins (e.g., phenol or cresol novolak resins, copolymers such as those of phenol terpene, polyvinyl phenol, or bisphenol-A formaldehyde copolymers, bishydroxyphenyl alkanes or the like), or mixtures thereof. Particular preferred curing agents include modified and unmodified polyamines or polyamides such as triethylenetetramine, diethylenetriamine tetraethylenepentamine, cyanoguanidine, dicyandiamides and the like. If an accelerator for the curing agent is used examples of materials includes a modified or * unmodified urea such as methylene diphenyl bis urea, an irriidazole or a combination *:::: thereof. * * *

..* 35 Other Components and Additives S. * * S

S ** * * S *

* .. 11 It is contemplated that most nearly any additional chemicals, materials or otherwise may be added to the material if they are suitable for a chosen application of the material.

Other additives, agents or performance modifiers may also be included in the material as desired, including but not limited to an antioxidant, a UV resistant agent, a flame retardant, an impact modifier, a heat stabilizer, a colorant, a processing aid, a lubricant, a reinforcement (e.g., chopped or continuous glass, ceramic, aramid, or carbon fiber, particulates or the like). Liquid polysufides may be used to improve the environmental exposure of the adhesive such as exposure to humidity and salt water.

When determining appropriate components for the material, it may be important to form the material such that it will only activate (e.g., flow, foam or otherwise change states) at appropriate times or temperatures. For instance, in some applications, it is undesirable for the material to be reactive at room temperature or otherwise at the ambient temperature in a production environment. More typically, the material becomes activated to flow at higher processing temperatures. As an example, temperatures such as those encountered in an automobile assembly plant may be appropriate, especially when the material is processed along with the other components at elevated temperatures or at higher applied energy levels, e.g., during painting preparation steps. Temperatures encountered in many coating operations (e.g., in a paint and/or e-coat curing oven), for instance, range up to about 250°C or higher.

The relative proportions of the materials that should be used will depend upon the use envisaged for the material. The first component of the present invention may be made in any suitable manner. For example it may be prepared by extrusion, blow moulding, injection moulding, vacuum forming and other suitable techniques. The attachment means may be provided as part of the initial component fabrication process, for example a profile containing the attachment means may be extruded and if necessary die cut to provide the desired component. Alternatively the * component provided with the attachment means can be produced by injection * moulding. As a further alternative the component may be produced by stamping from a sheet of material such as an extruded sheet, the stamp being such as to * .: * 35 provide the means of attachment. * *. ** * * S S * S. * * ** 12

The techniques of the present invention may be employed with a wide variety of shapes of second component. For example it may allow the first component to be attached to the flat surface of a second component. Alternatively it can allow the first component to be attached to a second component having an undulating surface. In a further embodiment the first component may be coiled within a cavity provided by the second component and attached thereto by the means of attachment. This is particularly useful when the material is to be foamed to fill the cavity to provide sound insulation and/or reinforcement, In this embodiment a hole or slot can be provided in one end of the component and the means of attachment may be provided at the other end of the attachment in this way the component can be coiled and the means of attachment passed through the hole in the component and also through a hole in the second component to secure the coil of the first component and attach it to the second component.

The component of the invention may be used to reinforce structural members of an article of manufacture. When used for reinforcement, the material may be employed by itself, it may be employed in conjunction with other materials (e.g., a backing), may be applied to a carrier member or the like.

According to one embodiment, the component of the present invention is attached to a carrier member using the attachment means to form a reinforcement member and the reinforcement member is inserted within a cavity formed by a structural member of an automotive vehicle. The structural member of the automotive vehicle may be nearly any member of the vehicle including, but not limited to, frame members, body member, pillar structures, closure panels, roof assemblies, bumpers, combinations thereof or the like.

The carrier member may be selected from a variety of conventional and novel configurations. The material of the present invention may thus be applied to a carrier member, such as a molded, extruded or stamped member (e.g., metal or plastic, foamed or unfoamed; exemplary materials of which include aluminum, magnesium, * ** titanium, steel, molding compound (e.g., sheet or bulk molding compound), polyamide (e.g., nylon 6 or nylon 6,6), polysulfone, thermoplastic imide, polyether imide, polyether sulfone or mixtures thereof. * * . * 35

The present invention is illustrated by reference to the accompanying drawings in which * * . * * ** * * S * ** 13 Figure 1 shows five different components provided with attachments according to the invention.

Figure 2 shows one of the components shown in Figure 1 with the attachment means rotated into the attachment position.

Figure 3 shows the component of Figure 2 attached to a second component.

Figure 4 shows a component which can be coiled to be attached within a cavity.

Figure 5 shows an alternate form of a component that can be coiled upon itself.

Figures 6 and 7 show the component shown in Figure 4 coiled and attached within a cavity.

Figure 1 shows five circular die stamped components (1) each provided with an integrally formed attachment means (2), (3), (4), (5) and (6) in the plane of the component (1) which can be rotated to stand proud of the plane of the component as shown in Figure 2. Figure 3 shows the component shown in Figure 2 attached to a metal component (7) of a vehicle sub frame.

Figure 4 shows a component (8) provided with two attachment means (9) and (10) which can be secured into slots (11) and (12) to enable the component to be coiled.

Figure 5 shows a component (13) provided with an attachment means (14) which can pass through a hole (15) provided in the component to allow itto be coiled.

Figure 6 shows the component of Figure 5 coiled within a cavity (16) of a vehicle frame and Figure 7 is a cross section of the cavity shown in Figure 6. * ** * S * * S. *S** S * *SS*

-*** S

S

S *. *5 * S I * S ** * * S S * 14

Claims

CLAIMS1. A component provided with an integral means for attachment lying substantially in the plane of the component which can be rotated relative to the plane of the component to provide an attachment means standing proud from the plane of the component.
2. An assembly comprising a first component attached to a second component wherein the attachment comprises an integral part of the first component which stands proud of the plane of the first component and is secured within an orifice provided in the second component.
3. A process for attaching a first component to a second component comprising providing a component which contains an integral means for attachment lying substantially in the plane of the component and which can be rotated relative to the plane of the component to provide an attachments means standing proud from the plane of the component on the surface of a second component which is provided with one or more orifices for receipt of the attachment comprising rotating the attachment means from the plane of the component to pass through the orifice to attach the first component to the second component.
4. A component according to Claim 1 made of a synthetic resin based material.
5. A component according to Claim 4 in which the synthetic resin based material can be processed by calending, injection moulding, blow moulding or extrusion.
6. A component according to any of the preceding claims in which the material is foamable and is such that it can be foamed after it has been attached to the second component. * * * * * S.*****
7. A component according to Claim 6 in which the component is employed in automobile manufacture and the material is such that it is foamed at the * ** * 35 temperatures experience in the vehicle paint oven or e-coat oven.S S. S. * . * * SS

S S * 15
8. The use of a component according to any of the preceding claims to perform a sealing function.
9. The use of a component according to any of Claims 1 and 4 to 7 to provide an acoustic baffle.
10. The use of a component according to any of Claims I and 4 to 7 to perform a reinforcing function.
11. A process for the production of a component according to Claim 1 wherein the attachment means is provided as part of the component fabrication process.
12. A process according to Claim 11 in which a profile containing the attachment means is extruded and die cut to provide the component.
13. A process according to Claim 11 comprising injection moulding.
14. A process according to Claim 11 wherein the component is produced by stamping from a sheet of material the stamp being such as to provide the means of attachment.
15. An assembly according to Claim 2 wherein the first component is attached to the flat surface of a second component.
16. An assembly according to Claim 2 wherein the first component is attached to a second component having an undulating surface.
17. An assembly according to Claim 2 in which the first component is coiled within a cavity provided by the second. *

*,,.
18. An assembly according to Claim 17 in which the material is foamable to fill the cavity to provide sound insulation and!or reinforcement.
19. An assembly according to Claim 17 in which a hole is provided towards one end of the component and the means of attachment is provided towards the ** *, other end wherein the component is coiled and the means of attachment * * * * S * * * * * 16 passes through the hole in the component and also through a hole in the second component to secure the coil of the first component and attach it to the second component.
20. An assembly according to Claim 2 in which the second component is a carrier member. * * * * .* *.S* * S *SSSS **S *S * S. *. * S I * * *S * * SS * 17