Patent Application
20140035309
The present invention relates generally to vehicle body panels. More particularly, this invention relates to the prevention of air flow through the connection of two or more vehicle body panels.
A frequent customer complaint which engineers strive to minimize is the noise heard by the user in the cabin of the vehicle during vehicle operation. These noises, commonly wind noises, are often created at the seam or connection of a plurality of body panels of a vehicle. A common area creating a high turbulence and therefore a high noise is the area where the fender and the side member of a vehicle meet. These two body members are traditionally bolted together and create a seam at either side of the vehicle windshield.
As the vehicle is in motion, air flows through the engine cavity and out through the seam created between the fender and the side member. Furthermore, air flows over the hood of the vehicle to the area where the seam connecting the fender and the side member is located. Air flowing from these various locations mixes and creates a high turbulence area (see reference numeral 46 at
The present invention relates to a method and apparatus for blocking the passage of air through a connection portion of two vehicle body portions. A first vehicle body portion is provided having a generally planar first surface. Expandable foam is mounted to the first surface of the first vehicle body portion. A second vehicle body portion having a generally planar second surface is connected to and overlapping the first surface of the first vehicle body portion thereby fully covering the expandable foam. The expandable foam expands when heated to a temperature of between 200 and 450 degrees Fahrenheit and is operable to expand to fill gaps. After baking, the foam forms a barrier between the first vehicle body portion and the second vehicle body portion which prevents the passage of air through the seam thereby preventing turbulence and noise heard by the occupant of a vehicle.
A method is further provided for blocking the passage of air through the connection portion of two vehicle body portions. The method includes the steps of placing an expandable foam on a first vehicle body portion, overlapping the second vehicle body portion over the expandable foam, securing the second vehicle body portion to the first vehicle body portion, and heating the first vehicle body portion, the second vehicle body portion, and the expandable foam allowing the expandable foam to expand and fill gaps to block the passage of air between the first vehicle body portion and the second vehicle body portion thereby reducing the noise heard by the occupant of the vehicle.
The present invention relates to a method and apparatus for preventing the flow of air through two body portions or panels. An expandable foam is mounted to one of these panels and the panels are thereafter secured to one another. During the baking process of the vehicle body, the expandable foam expands to fill gaps between the two portions to block air flow between the portions. The expandable foam blocks the air flow and thereby prevents turbulent mixing of the air flow flowing between the vehicle body portions and the air flow flowing over the vehicle hood. This turbulence is created near the windshield of the vehicle and subsequently the decrease in turbulence reduces the noise heard by the vehicle occupant.
The vehicle 10 further includes a grille 26 operable to accept the flow of air 25 into the vehicle engine cavity. Air 25 flows through the engine cavity and out the seam 20. Furthermore, the vehicle 10 includes a vehicle hood 45. Air created when the vehicle 10 is in motion passes over the hood 45, as illustrated by reference numeral 44. The air 25 flowing out the seam 20 and the air 44 flowing over the vehicle hood and over the vehicle windshield 12 creates turbulence 46 and significant noise to the vehicle occupant. The seam 20 is created by an overlap 30 of the side member 18 and the fender 22.
The expandable foam 150 is placed between two body portions 118 and 122. The side member 118 includes a an exterior surface, or first surface 119. The first surface 119 is generally planar and operable to accept the double sided tape of the expandable foam 150. The exterior surface, or first surface 119, is a surface on an exterior body panel (side member 118) of a vehicle component. This surface is traditionally covered with a coating, or paint. The expandable foam 150 rests on and is mounted to the first surface 119 of the side member 118. The fender 122 is positioned and mounted 170 over the expandable foam 150. The fender 122 includes an exterior surface, or upper surface 123, and a lower surface 127. The exterior surface, or upper surface 123, is a surface on an exterior body panel (fender 122). This surface is traditionally coated with covered with a coating, or paint. When the fender 122 is mounted securely to the side member 118, the lower surface 127 of the fender 122 comes into close contact with, or comes close to contact with the expandable foam 150 and the first surface 119 of the side member 118. The fender 122 is mounted to the side member 118 by means of a plurality of connection portions 172, 174. The expandable foam 150 is used to seal, or block airflow between, or to prevent the escape of air out of the seam between two exterior vehicle body portions. In this embodiment, these portions are the fender 122 and the side member 118.
A method of blocking the passage of air through the connection portion of two vehicle body portions, the method comprising the steps of, placing expandable foam on a first vehicle body portion, overlapping the second vehicle body portion over the expandable foam, securing the second vehicle body portion to the first vehicle body portion, and heating the first vehicle body portion, the second vehicle body portion and the expandable foam allowing the expandable foam to expand and block the passage of air between the first vehicle body portion and the second vehicle body portion. In the present embodiment, the expandable foam is a sticker. The method further includes the step of removing a sticker back before application to the first body portion. The first vehicle body portion, the second vehicle body portion and the expandable foam is heated to a temperature between 200-450 degrees Fahrenheit. After this baking process, the foam expands to fill any gaps to prevent the flow of air. The blocked air prevents/minimizes the turbulent mixing of the air flow flowing between the first and second vehicle body portions and the air flowing outside the vehicle. Without this blocking, noise can be heard by the customer within the vehicle cabin. Air is prevented from flowing, and thus noise is prevented.
The baking as discussed above is carried out simultaneously with the baking process already being carried out. The baking process is traditionally implemented to bake on paint, coatings or set and secure other materials. The process of baking the expandable foam does not require it's own baking process. The expandable foam of the present invention is expanded during the standard process already in place. This minimizes cost and energy required in manufacturing. The heating of the first body portion (side member), the second body portion (fender) and the expandable foam occurs during a standard baking process already used to cure vehicle body coatings.
This invention is not restricted to the illustrative examples and embodiments described above. The embodiments are not intended as limitations on the scope of the invention. Methods, apparatus, compositions, and the like described herein are exemplary and not intended as limitations on the scope of the invention. Changes therein and other uses will occur to those skilled in the art. The scope of the invention is defined by the scope of the appended claims.
