WO2016160689A1

WO2016160689A1 - Hinge pin and seal assembly

Info

Publication number: WO2016160689A1
Application number: PCT/US2016/024494
Authority: WO
Inventors: Todd R. Deachin; Gary COLTSON
Original assignee: Zephyros, Inc.
Priority date: 2015-03-27
Filing date: 2016-03-28
Publication date: 2016-10-06

Abstract

A device comprising a unitary structure including a rigid polymeric pin structure (12) including one or more openings (30) and a sealant material (22) located within the one or more openings and in direct contact with one or more surfaces of the polymeric pin structure (12).

Description

HINGE PIN AND SEAL ASSEMBLY

Technical Field

[001] The present teachings relate generally to a hinge and seal assembly including a hinge pin and sealing material associated with the hinge pin.

Background

[002] The transportation industry continues to require methods of sealing that prevent water from contacting joint areas within vehicle cavities, especially joints where there is direct metal to metal contact. Such contact is especially common where hinges are utilized. It is desirable that corrosion be avoiding in such joint areas to avoid deterioration of the joints.

[003] There is thus a need for a sealing assembly that is specifically adapted to hinge joints (and possibly other joints) for avoiding corrosion and deterioration of the joint and/or any structure adjacent to or adjoining the joint.

Summary of the Invention

[004] The teachings herein provide a solution for the issues set forth above by providing for a sealing device for use in combination with a hinge or other device for connecting two portions, the sealing device including a pin and a sealing material associated with the pin.

[005] In a first aspect the present teachings contemplate a device comprising a unitary structure including a rigid polymeric pin structure including one or more openings, and a sealant material located within the one or more openings and in direct contact with one or more surfaces of the polymeric pin structure. The sealant material may be located substantially within the confines of the pin structure prior to an activation step. The sealant material may be an activatable material. The device may be located in contact with a hinge structure. The unitary structure may be formed by an injection molding or extrusion process. The device may be located onto a bolt that extends through an opening. The opening may be located on a hinge structure. The device may seal an opening on a metallic structure. The device may be located in contact with a bolt that connects a first vehicle structure to a second vehicle structure. The device may be located in contact with a bolt that connects a first metallic vehicle structure to a second metallic vehicle structure. The device may include an opening for receiving a bolt. The opening for receiving the bolt may be formed substantially of the sealant material. The opening may receive the device. The sealant material may be an activatable material which expands upon contact with a stimulus, which may be heat. The sealant material may include an ethylene methyl acrylate in an amount of at least about 20% by weight. The sealant material may include an ethylene vinyl acetate copolymer in an amount of at least about 20% by weight. The rigid polymeric pin structure may include a substantially flat head portion. The rigid polymeric pin structure may include a substantially flat head portion and a plurality of ribs extending from the head portion. The rigid polymeric pin structure may include a substantially flat head portion and at least two ribs extending from the head portion. The rigid polymeric pin structure may include a substantially flat head portion and at least four ribs extending from the head portion.

[006] The teachings herein further envision a hinge assembly including a hinge and an opening located therein, wherein the opening receives a device, including a pin structure and sealing material as described herein. The device described herein may also be utilized to seal a joint structure.

[007] The present teachings further provide for a method of forming a joint in a vehicle structure comprising: providing a first member having a first opening formed therein; locating a bolt through the first opening; locating the device onto the bolt; providing a second member having a second opening formed therein; and locating the first member and device into contact with the second opening such that the device enters into and at least partially through the opening.

[008] The teachings herein contemplate a device and method for the sealing of openings with a sealing assembly including a pin and sealant material associated with the pin. The combination of the pin and sealant material may allow for effective sealing of an opening where water entry would be detrimental. The device disclosed herein may further be utilized to seal joints where metal on metal contact occurs.

Description of the Drawings

[009] Fig. 1 shows a perspective view of an illustrative example of the hinge and sealing assembly of the present teachings.

[0010] Fig. 2A shows a perspective view of an illustrative example of the sealing assembly of the present teachings.

[0011] Fig. 2B shows a perspective rear view of the sealing assembly of Fig. 2A.

[0012] Fig. 3 shows a perspective view of the sealing assembly of Fig. 2A located into an opening.

[0013] Fig. 4 shows a perspective view of a bolt for receiving the sealing assembly of Fig. 2A. Detailed Description

[0014] This application claims the benefit of the filing date of U.S. Provisional Application number 62/139,356, filed on March 27, 2015, the entirety of the contents of that application being hereby incorporated by reference for all purposes.

[0015] The present teachings meet one or more of the needs specified above by providing a pin structure and a sealant material in association with the pin structure. The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the teachings, its principles, and its practical application. Those skilled in the art may adapt and apply the teachings in its numerous forms, as may be best suited to the requirements of a particular use. Accordingly, the specific embodiments of the present teachings as set forth are not intended as being exhaustive or limiting of the teachings. The scope of the teachings should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. Other combinations are also possible as will be gleaned from the following claims, which are also hereby incorporated by reference into this written description.

[0016] The present teachings allow for improved sealing of an opening in a joint with a pin structure in association with a sealing material. The unitary structure disclosed herein may include an activatable sealing material and pin structure. The pin structure may be comprised of a rigid polymeric material that is dissimilar to that of sealing material. The sealant material may comprise or may consist essentially of a non-rigid activatable material. The sealant material and pin structure may be injection molded or extruded to form a unitary device. The sealant material and pin structure may be co-injection molded or co- extruded to form a unitary device.

[0017] The pin structure may be shaped to include one or more openings for receiving the sealant material. The openings may be formed having the same shape or a different shape as other openings. The pin structure may include a first set of openings located on a first portion of the pin structure and a second set of openings located on a second portion of the pin structure. A portion of the pin structure may be cone-shaped. A portion of the pin structure may be cylindrical in shape. The pin structure may include a head portion and plurality of ribs extending from the head portion. The ribs may be located about the sealant material such that the activation of the sealant material may be guided by the ribs, such that the ribs promote complete sealing about the entirety of the pin structure. The ribs may act to separate sections of sealant material in its green (pre-activated) state. The ribs may each be substantially equidistant from any adjacent ribs. [0018] The sealant material may consist essentially of an activatable material. The sealant material may be formed so that the entirety of the sealant material lies within the confines of the pin structure prior to any activation of the sealant material. The sealant material may form a mechanical connection with the pin structure. The sealant material may be adhered to the pin structure via an adhesive. The sealant material located in contact with the pin structure may be adhered to the pin structure by a tacky nature of the activatable material that forms the sealant material. The sealant material and pin structure may be adhered to one another during an injection molding process. The connection between the sealant material and pin structure may be of sufficient strength so that when the pin structure is located into an opening the sealant material and pin structure remain connected at least until the sealant material undergoes expansion.

[0019] The sealant material may be a tacky material and may include a removable film layer to allow for handling. The tacky nature of the sealant material may promote adhesion between the sealant material and pin structure. Alternatively, the sealant material may be substantially dry to the touch.

[0020] The pin structure may be a push-pin pin structure. The pin structure may include a head portion and shank portion such that the diameter of the shank exceeds the diameter of the head so that the head can be easily located into and through an opening.

[0021] The size of the sealant material and pin structure may depend upon the size of the opening through which the expandable sealant material and integrated pin structure is located. The thickness of the expandable sealant material may be at least about 0.1 mm. The thickness of the expandable sealant material may be less than about 50mm. The thickness of the expandable sealant material may be from about 0.5mm to about 20mm. The thickness of the expandable sealant material may be less than about 10mm.

[0022] After placement of the sealant material and pin structure through an opening, the sealant material may expand according to a predetermined set of conditions. For example, exposure to certain levels of heat may cause the activatable sealant material to expand. The heat may be provided by an oven. The heat may be provided by an induction heating device. The volumetric expansion of the sealant material may vary depending upon the sealing needs of a particular opening. The sealant material may expand at least about 100% as compared to the unexpanded (green state) sealant material. The sealant material may expand less than about 2000%. The sealant material may expand at least about 500%, at least about 1000%, or more. The sealant material may expand less than about 1000% or even less than about 500%.

[0023] The expandable sealant material may be generally dry to the touch or tacky and may be shaped in any form of desired pattern, placement, or thickness. Though other heat- activated materials are possible for the sealant material a preferred heat activated material is an expandable polymer or plastic, and preferably one that is foamable. The sealant material may be a relatively high expansion foam having a polymeric formulation that includes one or more of an epoxy resin, an acetate (e.g. ethylene vinyl acetate), a thermoplastic polyether, an acrylate and/or a methacrylate (e.g., a copolymer of butyl acrylate and methyl acrylate), an epoxy/elastomer adduct, and one or more fillers (e.g., a clay filler, and/or a nanoparticle- containing filler). Preferred thermally expandable sealant materials are disclosed in U.S. Patent Nos. 7,313,865; 7, 125,461 ; and 7, 199, 165, incorporated by reference herein for all purposes. For example, and without limitation, the foam may also be an EVA/rubber based material, including an ethylene copolymer or terpolymer that may possess an alpha-olefin. 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. Suitable expandable sealant materials include those available from L&L Products, Inc. under the designations L7220, L2821 , L1066, L205, L2010, L2105, L2108A, L2806, L2811 , L4200, L4141 , L4161 , L4315, L5510, L5520, L5540, L5600, L5601 , L7102, and L7104.

[0024] A number of sealing materials may also be used for the sealant material. A typical foam includes a polymeric base material, such as one or more ethylene-based polymers which, when compounded with appropriate ingredients (typically a blowing and curing agent), will expand and cure in a reliable and predictable manner upon the application of heat or the occurrence of a particular condition. From a chemical standpoint for a thermally- activated material, the foam is usually initially processed as a flowable material before curing, and upon curing, the material will typically cross-link making the material incapable of further flow. The sealant material may include an ethylene methyl acrylate in an amount of at least about 5% by weight, at least about 15% by weight or even at least about 20% by weight. The sealant material may include an ethylene vinyl acetate copolymer in an amount of at least about 5% by weight, at least about 15% by weight or even at least about 20% by weight.

[0025] The expandable sealant material and integrated pin structure of the present invention may be installed into an automotive vehicle, although it may be employed for other articles of manufacture such as boats, buildings, furniture, storage containers or the like. The sealing assembly may be utilized for connecting a door hinge to a vehicle pillar. The sealant material and pin structure may be used to seal a variety of components of an automotive vehicle including, without limitation, body components (e.g., panels), frame components (e.g., hydroformed tubes), pillar structures (e.g., A, B, C or D-pillars), bumpers, roofs, bulkheads, instrument panels, wheel wells, floor pans, door beams, hem flanges, vehicle beltline applications, doors, door sills, rockers, decklids, hoods or the like of the automotive vehicle. [0026] As shown for example in Fig. 1 , the hinge and seal assembly 10 may include a pin structure 12 in combination with a sealant material 22. A hinge 14 includes an opening 16 for receiving the pin structure 12.

[0027] Figs. 2A and 2B provide additional detail of the pin structure 12 in combination with the sealant material 22. A plurality of openings 30 are formed in the pin structure 12 for receiving the sealant material 22. The pin structure includes a flat head portion 20 with a plurality of ribs 24 extending from the head portion 20. The pin structure may also include an opening 28 for receiving a bolt (not shown).

[0028] As shown in Fig. 3, the pin structure 12 and associated sealant material 22 are located into an opening 16, whereby, upon activation of the sealant material, the opening is sealed. Fig. 4 provides a view of the opening 16 and bolt 26 that will receive the sealing assembly including the pin structure and associated sealing material (not shown).

[0029] Any numerical values recited herein include all values from the lower value to the upper value in increments of one unit provided that there is a separation of at least 2 units between any lower value and any higher value. As an example, if it is stated that the amount of a component or a value of a process variable such as, for example, temperature, pressure, time and the like is, for example, from 1 to 90, preferably from 20 to 80, more preferably from 30 to 70, it is intended that values such as 15 to 85, 22 to 68, 43 to 51 , 30 to 32 etc. are expressly enumerated in this specification. For values which are less than one, one unit is considered to be 0.0001 , 0.001 , 0.01 , or 0.1 as appropriate. These are only examples of what is specifically intended and all possible combinations of numerical values between the lowest value and the highest value enumerated are to be considered to be expressly stated in this application in a similar manner. As can be seen, the teaching of amounts expressed as "parts by weight" herein also contemplates the same ranges expressed in terms of percent by weight. Thus, an expression in the Detailed Description of the Invention of a range in terms of at " x parts by weight of the resulting polymeric blend composition" also contemplates a teaching of ranges of same recited amount of "x" in percent by weight of the resulting polymeric blend composition."

[0030] Unless otherwise stated, all ranges include both endpoints and all numbers between the endpoints. The use of "about" or "approximately" in connection with a range applies to both ends of the range. Thus, "about 20 to 30" is intended to cover "about 20 to about 30", inclusive of at least the specified endpoints.

[0031] The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. The term "consisting essentially of" to describe a combination shall include the elements, ingredients, components, or steps identified, and such other elements ingredients, components, or steps that do not materially affect the basic and novel characteristics of the combination. The use of the terms "comprising" or "including" describe combinations of elements, ingredients, components, or steps herein also contemplates embodiments that consist essentially of the elements, ingredients, components or steps. By use of the term "may" herein, it is intended that any described attributes that "may" be included are optional.

[0032] Plural elements, ingredients, components or steps can be provided by a single integrated element, ingredient, component, or step. Alternatively, a single integrated element, ingredient, component, or step might be divided into separate plural elements, ingredients, components, or steps. The disclosure of "a" or "one" to describe an element, ingredient, component, or step is not intended to foreclose additional elements, ingredients, components, or steps.

[0033] It is understood that the above description is intended to be illustrative and not restrictive. Many embodiments as well as many applications besides the examples provided will be apparent to those of skill in the art upon reading the above description. The scope of the invention should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. The omission in the following claims of any aspect of subject matter that is disclosed herein is not a disclaimer of such subject matter, nor should it be regarded that the inventors did not consider such subject matter to be part of the disclosed inventive subject matter.

Claims

Claim 1 : A device comprising:

a unitary structure including:

a rigid polymeric pin structure including one or more openings; and a sealant material located within the one or more openings and in direct contact with one or more surfaces of the polymeric pin structure.

Claim 2: The device of claim 1 , wherein the sealant material is located substantially within the confines of the pin structure prior to an activation step.

Claim 3: The device of claim 1 or claim 2, wherein the sealant material is an activatable material.

Claim 4: The device of any of the preceding claims, wherein the device is located in contact with a hinge structure.

Claim 5: The device of any of the preceding claims, wherein the unitary structure is formed by an injection molding or extrusion process.

Claim 6: The device of any of the preceding claims, wherein the device is located onto a bolt that extends through an opening.

Claim 7: The device of claim 6, wherein the opening is located on a hinge structure.

Claim 8: The device of any of the preceding claims, wherein the device seals an opening on a metallic structure.

Claim 9: The device of any of the preceding claims, wherein the device is located in contact with a bolt that connects a first vehicle structure to a second vehicle structure.

Claim 10: The device of any of the preceding claims, wherein the device is located in contact with a bolt that connects a first metallic vehicle structure to a second metallic vehicle structure. Claim 11 : The device of any of the preceding claims, wherein the device includes an opening for receiving a bolt.

Claim 12: The device of claim 11 , wherein the opening for receiving the bolt is formed substantially of the sealant material.

Claim 13: The device of any of the preceding claims, wherein the sealant material is an activatable material which expands upon contact with a stimulus.

Claim 14: The device of any of the preceding claims, wherein the sealant material includes an ethylene methyl acrylate in an amount of at least about 20% by weight.

Claim 15: The device of any of the preceding claims, wherein the sealant material includes an ethylene vinyl acetate copolymer in an amount of at least about 20% by weight.

Claim 16: The device of any of the preceding claims, wherein the rigid polymeric pin structure includes a substantially flat head portion.

Claim 17: The device of any of the preceding claims, wherein the rigid polymeric pin structure includes a substantially flat head portion and a plurality of ribs extending from the head portion.

Claim 18: The device of any of the preceding claims, wherein the rigid polymeric pin structure includes a substantially flat head portion and at least two ribs extending from the head portion.

Claim 19: The device of any of the preceding claims, wherein the rigid polymeric pin structure includes a substantially flat head portion and at least four ribs extending from the head portion.

Claim 20: A hinge assembly including a hinge and an opening located therein, wherein the opening receives the device of any of claims 1 through 19.

Claim 21 : Use of the device of any of claims 1 through 19 for sealing a joint.

Claim 22: A method of forming a joint in a vehicle structure comprising:

providing a first member having a first opening formed therein; locating a bolt through the first opening;

locating the device of any one of claims 1 through 19 onto the bolt;

providing a second member having a second opening formed therein;

locating the first member and device of claims 1 through 19 into contact with the second opening such that the device enters into and at least partially through the opening.