The present invention relates to a passive restraint for an automobile, and more particularly, to a knee blocker for automotive applications that is posi¬ tioned under the steering column forward of the knees.

Recently, the National Highway Traffic Safety Administration promulgated Standard No. 208 entitled

10 Occupant Crash Protection which is applicable to all automo¬ biles manufactured by 1990 and requires that the imping¬ ing load upon the knee and into the femur or thigh area during an automobile crash should not be more than 1,021 kg per leg. If the driver does not wear a lap

15 belt, the forward motion of the driver into the instrument panel creates a femur load in both legs vastly greater than 1,021 kg. As a result thereof, the automobile industry has actively been pursuing various designs for passive restraints which absorb the impact

20 when the knees are forced into the instrument panel to create an impinging load on the femur or thigh area during an automobile crash of less than 1,021 kg. Such a design is the subject of U.S. Patent 4,721,329 to

_?c . Braήtman et al. issued January 26, 1988.

Typically, these passive restraints include a suitable energy-absorption material that is enveloped in a cavity of the passive restraint. In the Brantman ref¬ erence, an elastic polyethylene foam layer having a den¬ sity of 96 kg-m ^"3 , and 3.8 cm thick absorbs energy upon impact of the knees. In addition, in Brantman, to provide further energy absorption an outer layer is formed of crushable polystyrene foam 3.8 cm thick, and having a density of 32.02 kg.m ^"3 . It has been found extremely expensive, however, during the manufacturing process to produce a passive restraint having a layer of crushable pellets and a layer of polyethylene foam material as is disclosed in Brantman.

In order to alleviate this cost, the present invention includes a passive restraint defining a frame having an internal cavity including microsphere-filled thermoset resin pellets. These thermoset resin pellets are the subject of U.S. Patent 4,737,^07 issued April 12, 1988 to Joseph ycech. In contrast to the Brantman reference, the necessity of a polyethylene foam material being intermixed with crushable pellets in an internal cavity of the passive restraint is alleviated by this invention.

As further background, plastic materials are currently used for filling and reinforcing structural members. Expanded polyurethane foam is known to be used for filling structural members to improve sound dampen¬ ing, thermal insulating and crush strength qualities of the structures. Plastic fillings are used in boats to fill flotation cavities and in vehicles to act as sound

baffles and reinforcements for hollow structural mem¬ bers.

The most common type of plastic used in such applications is expanded polyurethane foam. In struc¬ tural reinforcement applications, expanded polyurethane foam lacks compressive and tensile strength and has extremely low heat resistance.

In recent years, specialized plastic reinforce¬ ments have been developed wherein macrospheres are formed of glass microspheres which are combined with a phenolic binder. The macrospheres are then coated with a phenolic resin which increases the strength and shell thickness of the macrospheres but also adds weight to the final product. After coating with a phenolic resin, the macrospheres are coated with a B-staged phenolic or epoxy which permits the macrospheres to be bound together to form a structural reinforcement. Examples of two types of such macrospheres are two materials manufactured by 3M Company and identified by the follow¬ ing trade designations: M27X for uncoated macrospheres and M35EX for phenolic-coated macrospheres. The above macrospheres are known to be used as structural rein¬ forcements for vehicles.

Another approach to improving the performance of plastic fillers to function as reinforcements is to provide polystyrene beads which are coated with an epoxy. One such product is sold by . R. Grace Company under the tradename Ecosphere. The polystyrene bead has an epoxy coating which is in the form of a cured shell. The polystyrene bead with cured shell may be coated with an adhesive and used as a constituent element for struc-

tural fillers. However, the coated polystyrene beads are expensive, have only slightly greater compressive strength than polyurethane fillers and have only limited heat resistance due to the fact that the polystyrene substrate may begin to melt at temperatures as low as 98.9°C.

In terms of processing techniques, it is known to extrude thermoset materials by first B-staging the thermoset materials by heating them prior to extrusion. The B-staged thermoset materials emulate thermoplastic materials and are extrudable to a limited extent. How¬ ever, the high viscosity of B-staged thermoset materials prevents incorporation of a high percentage of micro- sphere fillers since the heat and friction developed during the mechanical mixing of the B-staged resin causes the microspheres to be crushed and would limit the weight savings sought to be realized by the incor¬ poration of lightweight microsphere fillers.

Prior art plastic reinforcements fail to pro¬ vide a lightweight yet strong reinforcement which is thermally stable and competitive in cost to other types of structural reinforcements. These and other problems and disadvantages are overcome by the present invention as summarized below.

Figure 1 is a side elevational schematic view of an illustrated embodiment of an apparatus for making the pellets used in the present invention.

Figure 1a is a perspective view of the contin¬ uous strand and magnified perspective view of a pellet made in the apparatus of Figure 1.

Figure 2 is an end elevational view of a kneader-extruder die used for making pellets used in the present invention.

Figure 3 is a side elevational view of a kneader-extruder die used for making pellets used in the present invention.

Figure 4 is a perspective view of an illus¬ trated embodiment of a bulk mixer and hydraulic press extruder for making the pellets used in the present invention.

Figure 5 is a perspective view of the drum and extrusion die used in the hydraulic press-type extruder and die as shown in Figure 4.

Figure 6 is a fragmentary side elevational view of the hydraulic press extruder and die as shown in Figure 4.

Figure 7 is a block diagram illustrating the steps of the methods used for making pellets used in the present invention.

Figure 8 is a front perspective view of a pre¬ ferred embodiment of the knee blocker for an automotive application of this invention.

Figure 9 is a side cross-sectional view of the knee blocker assembly of this invention.

Figure 10 is a front perspective view of the knee blocker assembly of this invention.

In its first aspect, this invention is a pellet comprising a continuous phase of a thermoset resin and a plurality of microspheres dispersed in said resin, each pellet having a coating of an adhesive. In a second aspect, this invention is a passive restraint system core for a vehicle comprising a pocket filled with a plurality of pellets, wherein each pellet comprises a continuous phase of a thermoset resin and a plurality of microspheres dispersed in said resin, each pellet having a coating of an adhesive.

In its third aspect, this invention is a passive restraint system assembly for a vehicle comprising:

a frame adapted for being secured to the vehicle and having a plurality of outer surfaces; a metal or plastic stamping layer disposed on one outer surface of said frame; a foam padding being disposed on another outer surface of said frame; and an energy absorbing core being dis¬ posed between said metal or plastic stamping and said foam padding;

said core being filled with a plurality of pellets, each said pellet comprising a continuous phase of a thermoset resin and a plurality of microspheres dispersed in said resin, each pellet having a coating of an adhesive.

This passive restraint system assembly provides a lightweight, strong, and thermally stable means for protecting a vehicle passenger in the event of a vehicle crash. These and other objects and advantages of this invention are apparent from the description which follows.

In its first aspect, this invention is a pellet comprising a continuous phase of a thermoset resin and a plurality of microspheres dispersed in said resin, each pellet having a coating of an adhesive. In the process for the manufacture of the pellets of the invention, the first step comprises mixing thermoset resin and microspheres. Examples of such thermoset resins include, for example, phenolic resins, epoxy resins, polyurethane resins, polyester resins, vinylester resins, melamine formaldehyde, urea formaldehyde, phenolic epoxy, epoxy-nylon, and other thermoset resins described in J. Shields, Adhesiυes Handbook, 3rd Ed. (1984), the relevant portions of which are hereby incorporated by reference. Preferably, the thermoset resin is a thermoset epoxy resin, vinylester resin, epoxy-nylon, or polyester resin. The thermoset resin in the pellets is preferably a low viscosity epoxy or polyester resin. The microspheres may be comprised of thermally unexpandable or expandable microspheres of organic materials or inorganic materials such as glass, ceramic, or thermoplastic materials.

Preferably the microspheres are comprised of boron silicate-glass, or a thermoplastic resin, such as, for example, polyvinylidene chloride. Preferably, such microspheres have a diameter of less than 400 microns.

Maximum strength and weight savings can be achieved by combining the resin with microspheres in the range of ratios of 1:2.75 to 3.5 parts by volume. Preferably, the resin and microspheres are combined in a weight ratio of between 1:0.15 to 1:0.35, more preferably in a ratio of from 1:0.20 to 1:0.35.

The mixture is cold extruded, preferably through a plurality of extrusion ports, to form at least one continuous strand which is deposited on an endless belt conveyor. The conveyor preferably moves at a speed substantially equal to the rate that the strand is extruded. The strand is a paste form mixture when extruded which is cured on the conveyor to form a solid strand, wherein the thermoplastic resin is either B-

-staged or completely cured. The term "B-stage" as used herein refers to the stage prior to crosslinking wherein the^thermosetting resin exhibits heat plastification characteristics of a resin which may be softened by heat and then regain its original characteristics upon cooling. This stage is further characterized by partial polymerization or curing to form an intermediate solid, semi-solid, or gel thermoplastic that is stable and storable at room temperature in the semi-solid form, and easily handled and capable of being formed into desired end product configurations prior to the formation of a final cured thermoset. The diameter of the pellets in preferably in the range of from 0.16 cm to 0.64 cm.

Following this curing stage, the strand is then chopped or otherwise formed into pellets. The pellets may be formed into structural reinforcements and cured in place in the structural members as described in Applicant's copending application Serial No. 811,041,

filed December 19, 1985, the disclosure of which is hereby incorporated by reference. The pellets are preferably coated with an adhesive prior to forming the pellets into structural reinforcements. The diameter of the pellets is preferably in the range of from 0.16 cm to 0.64 cm.

The mixing steps are performed at ambient tem¬ peratures or more preferably at a slightly elevated tem¬ perature below the B-stage temperature of the mixture. The mixture is preferably not B-staged in the mixer but is instead heated on the conveyor to a point above B- -stage for a time period sufficient to cure or B-stage the extruded strands within a very short period of time as they are conveyed to the pelletizer.

The pellets are intended to be used according to the present invention in a passive restraint for automobile applications.

The pellets comprise uncured thermoset resin which is intermixed with expanded microspheres and converted to its solid form. The pellets also preferably include thermally expandable microspheres which permit further reduction of the bulk density of the pellets. Alternatively, the pellet mixture may include a blowing agent which permits expansion of the pellets upon heating.

The pellets are preferably formed of a low viscosity thermoset resin such as a polyester resin or thermally curable epoxy resin. The pellets formed according to the process of the present invention are unique in that they are made by an extrusion process

which provides significant processing efficiencies. When the pellets are formed of thermoset resins, they are significantly stronger in terms of tensile and compressive strength as compared to thermoplastic pellets.

The pellets are preferably composed of the following constituents in the following approximate ranges:

TABLE I

Constituent Range

Polymeric Resin 100 resin weight

Organic or Inorganic 15-35 resin weight Pre-expanded microspheres ϋnexpanded Microspheres 0-10% resin weight

Curing Agent 0-3% resin weight

Wetting Agent 0-15% resin weight

The curing agent amount stated above would be appropri¬ ate for polyester or vinylester systems. If a one-part epoxy resin is used, the cure agent could be in the range of 1 to 10 percent resin weight, and if a two-part epoxy resin is used, the cure agent could be in the range of 0 to 50 percent resin weight. As is well-known in the industry, the quantity of curing agent depends upon resin and cure system. If a thermoplastic resin is used, a curing agent is generally unnecessary.

The apparatus for making the thermoset pellets of the present invention includes a batch mixer and extruder, or kneader-extruder, wherein the thermoset resin, microspheres and other constituents are combined and from which the mixture is extruded. The mixture is extruded on an endless belt conveyor in paste form as a continuous strand. The endless belt conveyor is substantially synchronously operated with the rate of extrusion since the strand has only limited compressive and tensile strength at the time it is extruded. If the endless belt conveyor were to run too quickly, the strand would be stretched or broken and if ran too slow¬ ly, the strand would accumulate on the conveyor. It is preferred to provide an extrusion die having a plurality of linear bores which are oriented at an acute angle, preferably less than 30°, relative to the top surface of the conveyor belt. The strength of the strand is increased as the mixture gels. Gelling can be acceler- ated by exposing the strand to a catalyzing environment, preferably under an infrared heater, as it passes along the conveyor. The strands are heated to above their B- -stage temperature on the conveyor for a time period sufficient to cure or B-stage the mixture. After gelling, the strands are tack-free, hardened, and

ductile. The strands are then conveyed to an unloading station wherein the strands are broken or cut into pellets.

The pellets are then coated with an adhesive by a tumbling process. The adhesive is comprised of a thermoset resin, which preferably has two percent or less tensile elongation. The resin coating is provided primarily to provide adhesion between pellets and to the frame of the passive restraint system. If the coating has low tensile elongation characteristics, the ultimate compression strength of the pellets and passive restraint made with the pellets will be enhanced. Also, the resin coating can improve moisture resistance of the pellets and passive restraints made thereby and assures good long-term strength.

If the process includes coating the pellets with an epoxy resin in the post-cure mixer, an aqueous epoxy resin dispersion can be used which includes from 0.25 to 1 percent resin weight of an accelerator such as pyridine (DMP 30) or 2-ethyl-4-methylimidazole (EMI 24) and from 2 to 4 percent by resin weight of a catalyst, _ι - preferably dicyandiamide.

The primary advantage of the method and appara¬ tus used in the present invention is that a simple and continuous process may be used to form highly filled, 0 high strength thermoset pellets which are then usable as a constituent in the manufacture of pre-cast passive restraint systems. In addition, the product made according to the process is superior to thermoplastic pellets in terms of strength and temperature resistance. The pellets made according to the process are also

superior to prior art B-staged thermoset pellets because they can be highly filled with unexpanded and expanded microspheres.

The primary advantage of the pellets is their high strength, ultra-low weight and low cost. Thermoset pellets have superior tensile strength and compressive strength as compared to thermoplastic pellets. Also, the thermoset materials have a higher temperature

10 resistance as compared to prior art thermoplastic pel¬ lets. Bulk density of the pellets formed according to the present invention may be as low as 192 kg«m~3 when no unexpanded microspheres are used and may be as low as approximately 144 kg«m"3 if thermally unexpanded 15 microspheres are included in the pellet mixture.

As is well-known, thermoset materials generally have greater compressive and tensile strength than ther¬ moplastic materials. When combining this strength ad¬

20 vantage with the above density levels, it will be read¬ ily appreciated that an extremely high strength and lightweight material is provided. Such a high strength, low density material is ideal for use in automotive - _j . applications where weight savings are important.

In a second aspect, this invention is a passive restraint system core for an vehicle comprising a pocket filled with a plurality of pellets, wherein each pellet 30 comprises a continuous phase of a thermoset resin and a plurality of microspheres dispersed in said resin, each pellet having a coating of an adhesive. The pocket may be a female pocket made by vacuum foaming. Preferably, the pocket comprises a molded plastic part. In this embodiment, the pellets are preferably coated with an

adhesive which is curable at ambient temperatures or in a low temperature oven bake system. This embodiment obviates the need for a vacuum-formed female pocket, and the exterior plastic surface of the part simplifies the attachment to the energy absorbing core of a foam padding or vinyl skin.

In its third aspect, this invention is a passive restraint system assembly for a vehicle comprising:

a frame adapted for being secured to the vehicle and having a plurality of outer surfaces; a metal or plastic stamping layer disposed on one outer surface of said frame; a foam padding being disposed on another outer surface of said frame; and an energy absorbing core being dis¬ posed between said metal or plastic stamping and said foam padding;

said core being filled with a plurality of pellets, each said pellet comprising a continuous phase of a thermoset resin and a plurality of microspheres dispersed in said resin, each pellet having a coating of an adhesive.

Preferably, this passive restraint system assembly is a knee blocker assembly that is positioned in the area of the instrument panel of an automobile that is under the steering column forward of the knees. The construction of this assembly basically consists of a one-piece metal or plastic stamping attached to the

frame of the car which is approximately 30.5 cm high and runs the full width of the car from hinge pillar to hinge pillar. The energy absorbing core is made by vacuum foaming a female pocket and inserting the cast pre-coated pellets into the female pocket. These pellets will act as a crushable medium in that when the knee impacts the lower instrument panel, energy is absorbed by the pulverization and crush of the media. This energy absorbing core can be attached to the metal or plastic panel at a position below the steering column in front of the driver by a variety of methods. First, the pre-cast part can be locked or trapped into the sheet metal or plastic at the top by a notch in the sheet metal or plastic. It can also be bonded to the metal or plastic stamping by means of a butyl type of adhesive. By a third means of attachment, the vacuum form sheet can be stapled to the metal or plastic stamping. When attached to the metal or plastic stamping, the outwardly facing side of the energy absorbing core is preferably covered with a 0.64-inch thick urethane foam with a vinyl skin attached thereto. The knee blocker is actually sandwiched between the metal or plastic stamping and the foam vinyl skin.

Another advantage of the method of the present invention is that the pellets can conceivably be made from any type of thermoset material.

Other objects, advantages and efficiencies of the present invention will become apparent upon review¬ ing the attached drawings in view of the following spe¬ cification and appended claims.

Re erring now to Figure 1, an apparatus 10 useful to manufacture the pellets incorporated in the present invention is schematically shown. The process of forming the pellets is schematically shown in Figure 7 and begins by combining thermoset resin, fillers and other constituents in a kneader-extruder 12. The kneader-extruder 12 preferably includes an S-shaped mixer element 14 which combines the pellet constituents at room temperature without heating the mixture, pro¬ vided that the resin viscosity is less than about 700 centipoises (cps). The kneader-extruder 12 includes a screw extrusion element 16 located in the lower portion of the kneader-extruder 12 which forces the mixture through an extrusion die 18 and onto an endless belt conveyor 20.

Referring now to Figures 2 and 3, the extrusion die 18 is shown to include a central cavity 22 in which the resin/filler mixture is forced. A plurality of lin¬ ear extrusion ports 24 extend from the central cavity 22 to an extrusion face 26 at an angle of 30° or less rela¬ tive to the top surface of the conveyor belt. The angle is an acute angle of incidence relative to the top sur- face of the conveyor belt 28 generally in the same direction as the conveyor belt 28 moves. The die 18 includes an externally threaded portion 30 on one end for attaching the die 18 to the kneader-extruder 12, as is well-known in the art. The extrusion face 26 is oriented at a 30° or smaller angle relative to the front end of the die 18 which is perpendicular to the top sur¬ face of conveyor belt 28. The precise angulation of the extrusion die ports 24 is preferred to be maintained at 30° or less to facilitate extruding the mixture on the conveyor belt 28 without breakage, stretching or com-

pacting. The conveyor belt 28 is preferably made of or coated with a polytetrafluoroethylene or silicon coating to prevent adhesion of the mixture to the belt.

The mixture is deposited on the conveyor belt e*

28 in paste form, as shown in Figures 1 and 1a. The continuous strand 32 is highly filled with microspheres to provide cohesiveness in the strand after the strand is deposited on the conveyor. The high degree of filler

₁₀ loading prevents distortion when the strand is heated during the gelling step. The extruded paste is differ¬ ent from thermoplastic extrusions which are extruded in their melted state. In contrast to thermoplastic extru¬ sions, the continuous strands made according to the

15 present invention are not melted. A limited amount of heat may be developed during the kneading and extruding processes as a result of friction generated by the mixing.

20 With certain viscous resins having favorable heat distortion characteristics, it is necessary to warm the resin mixture to permit sufficient filler loading to form a cohesive extruded paste. Resins having good heat _c - distortion characteristics generally have viscosity in excess of 700 cps. Extremely high viscosity resins hav¬ ing excellent heat resistance may be mixed with other compatible resins to reduce viscosity and aid in mixing with fillers. The viscosity of such resins prevents

30 adding enough filler at ambient temperature to form an extruded strand which will retain its extruded cross- -section after being deposited on the conveyor. Heating the resin mixture to between 51.6°C to 60.0°C lowers the viscosity of the resin to less than 700 cps and permits filler loading to between 20 and 35 percent of resin

weight which gives the extruded strand sufficient cohe- siveness after extrusion to be moved without distortion by the conveyor through the gelling step. Heating other types of resin above ambient but below B-stage may also permit increased filler loading. The extruded strand maintains its shape after being deposited in paste form on the conveyor belt because it is extensively loaded with lightweight fillers.

0 With resins having lower viscosity, additional heat is generally not necessary. Alternatively, the kneader-extruder 12 may include means for vibrating the die to reduce viscosity due to the thixotropic nature of the mixture and to aid in extrusion. 5

Referring now to Figures 4 through 6, an alter¬ nate mixer and extruder apparatus will be described. Instead of a kneader-extruder 12, a batch mixer 42 com¬ prising a feeder 44 loads the resin, fillers and other 0 constituents into a mixing drum 46. The mixture in the mixing drum 46 may be manually or power mixed to form a homogeneous mixture. The drum 46 is then placed in a press 48 having a compression element 50 for exerting a _?c . compressive force on the mixture in the drum 46 to cause the mixture to be extruded through the extrusion die 18 located at the base of the central cavity 22 and a plu¬ rality of extrusion ports through which the mixture is forced onto the top surface of the conveyor belt 28 of 30 the conveyor 20. The construction of the extrusion die 18 is substantially the same as the extrusion die of the kneader-extruder except that the central cavity is below the compression element 50 instead of being laterally adjacent the screw extrusion element 16. The orienta-

tion of the extrusion ports 24 relative to the conveyor is substantially the same for both apparatus.

The conveyor belt 28 preferably includes radiant heaters 34, or a catalyzing environment chamber, disposed adjacent the conveyor surface for accelerating the gelling process of the strands 32. It is possible to perform the process by allowing the strands to gel at room temperature without any expedient for gelling. However, for processing efficiency it is generally pre¬ ferred to accelerate the gelling process by subjecting it to a catalyzing environment chamber 34 wherein the continuous strands are gelled and detackified. The catalyzing environment chamber is preferably a radiant heater 34 but may alternatively contain an ultraviolet radiation source, a microwave radiation source, radio waves or a chemical vapor. By using a catalyzing envi¬ ronment chamber, the time required to gel the strands may be reduced to as little as 10 seconds or as long as 3 minutes but would preferably be a 60- to 90-second time period.

If the present mixture includes a blowing agent, or thermally expandable microspheres, the micro- spheres, or blowing agent, may be activated by the cata¬ lyzing environment chamber, or radiant heaters 34, caus¬ ing the strands to expand during the gelling process. The primary reason for including unexpanded microspheres or a blowing agent, is to reduce the density of the pel¬ lets. If expandable microspheres are included in the mixture, the quantity of expanded microspheres may be reduced accordingly.

The final step in the process is performed in a rotary chopping pelletizer 36 which chops the strands into generally cylindrical pellets 38. The pellets 38 are preferably 0.32 cm long cylinders which are 0.32 cm in diameter. The size of the pellets 38 is expected to vary from 0.16 to 0.64 of a cm in diameter and the pellets 38 are typically cut into cylindrical segments having the same length as they are in diameter. The strand must have more than 10 percent tensile elongation to be processed by a pelletizer. After pelletizing, the curing process may continue until the pellets have 6 to 8 percent tensile elongation.

After pelletizing, the pellets 28 are loaded into a post-cure mixer 40 and tumbled as they are coated with a B-staged epoxy resin or an epoxy resin dispersion in a solution. The epoxy resin is a heat curable resin preferably mixed with a cure agent. The coating may also be a polyester or vinylester. One epoxy resin that have produced good results is an Interez resin having the trade designation CMD 35201. A coating made with CMD 35201 and a curing agent had approximately 2 percent maximum tensile elongation. Pellets coated with the CMD 35201 had good moisture resistance which protects the long-term strength characteristics of the pellets.

Instead of coating the pellets 28, immediately after pelletizing they may be stored for later process- ing.

After the pellets 28 have been coated, they may be stored or transferred to a pre-cast reinforcement forming operating as described in my copending patent

application, Serial No. 811,041, filed December 19, 1985.

The pellets 38 in their simplest form are com¬ prised of thermoset resin, resin cure agent, and pre- tz

-expanded microspheres with the microspheres being in the range of 20-35 percent resin weight. Currently, experimentation with thermoset polyester resins and inorganic pre-expanded microspheres has resulted in the _ιn production of pellets wherein the microspheres may be added in the amount of 3έ times the resin volume. Fur¬ ther addition of microspheres results in excessive vis¬ cosity of the mixture and difficulty in extrusion which could be alleviated by adding a lubricating additive or

15 heating.

The bulk density of pellets made with only pre- -expanded microspheres may be as low as 192 kg-m ^"3 . If additional weight reduction is desired, the pellets may

20 include thermally expandable microspheres in addition to the pre-expanded microspheres wherein the bulk density of the pellets may be reduced to as low as 144 kg«m ^"3 .

__ Other additives such as curing agents, wetting agents or diluents may be added to the mixture to accelerate the curing of the resin or lubricate the resin keeping it flowable for processing by the kneader- -extruder.

30

The following table sets forth the constitu¬ ents, tradenames, generic composition and preferred and broad ranges of constituents.

TABLE II

Broad Pre

Generic Range as ferr Constituent Type Tradenames* % Resin Rang

Weight % Res

Thermoset Resin a. Polyester Altek Polyester Molding Resin 100% 100 USS Chem./LB804-31 USS Chem./MR13031 b. Vinylester USS Chem./MR 14059 100% 100 c. Epoxy Celanese/Epi-Rez SU 2.5/507 100% 100 Celanese/CMD35201 Shell/EPON 828/1031 Celanese/Epi-Rez 504

Microsphere a. Organic Phila. Quartz/Q-Cell 200 25-35% 25-3 Filler PA Industries/Extendospheres b. Glass Bubbles 3M Company/C-15 Grefco/Dicaperl HP (10-30 u) c. Thermoplastic Expancel 55DE

Curing Agent a. Organic Peroxide Tert Butyl Peroxy Diethylacetate Noury/Percadox 16 b. Dicyandiamide Celanese/DiCy c. Aliphatic Amine Epicure/826 Shell/Epon 871 Epicure/855 d. Anhydride Buffalo Color Corp/NADIC Methyl Anhydride

TABLE II (cont'd)

Broad Pr

Generic Range as fer Constituent Type Tradenames* % Resin Ra

Weight % R

Expansion Agent a. Expandable Expancel 55DU 3-10% 6- Microspheres b. Blowing Agent Uniroyal/Celogen TSH 0.25-3% 2-

Accelerators Tertiary Amines Benzyldimethylamine (2,4,6-tridi- 0-8% 4- methylaminoethyl phenol) (dimethyl* aminomethyl phenol) 2-ethyl-4- methylimidazole (EMI-24)

Wetting Agent a. Surfactant Butyl Glydicyl Ether 0-25% 6-1 or Diluent Cresyl glycidyl Ether Neopentyl Glycol b. Polymer Styrene 0-15% 5-1 c. Solvent Water 0-15% 5-1 Ether Ester

Plasticizers Polymer C.P. Hall/Paraplex G-30 0-15% 5-1

^■ The tradenames are listed by company name/trade designation as appropriate

If desired, pellets may be made according to the invention from only thermoset microsphere filler and curing agent.

Generally, the most important performance cri¬ teria for a reinforcement element is that it have the required ultimate strength and average crush load bear¬ ing capability. Another very important characteristic of a reinforcement is the mass of the reinforcement, especially in view of the current efforts to reduce weight in vehicles.

The ultimate strength of a reinforcement is vital to its impact resistance. In addition to ultimate strength, the average crush load is indicative of the load required to crush the reinforcement to a degree of time dependent deflection. The average crush load is important in analyzing the ability of the knee blocker to withstand sheer and bending loads. For desirable ultimate strength, it has been found that a low percent tensile elongation, such as 2 percent, provides relat¬ ively high ultimate strength characteristics. Converse¬ ly, higher percent tensile elongation characteristics, such as 6 to 7 percent tensile elongation, generally provide superior average crush load characteristics.

Desirable strength characteristics of reinforcements may be diminished over time, especially if exposed to moisture. Generally, the greater the percent tensile elongation of a given resin, the less resistant it is to moisture.

One final desirable characteristic of a knee blocker is its cost relative to other passive restraint systems that offer comparable protection.

One problem with heat-resistant thermoset resins is that they tend to be too viscous to mix with microspheres at ambient temperature. It has been found that the viscosity of a resin prior to adding the filler materials should be less than 700 centipoises. There¬ fore, to permit the use of viscous heat-resistant resins, it is necessary to warm the resin to a temper¬ ature above ambient temperature but below the B-stage temperature of the resin. As the resin is heated, its viscosity is reduced, and the microsphere fillers may be intermixed therewith.

In a preferred embodiment of the present inven¬ tion, a pellet having a percent tensile elongation of 6 to 8 percent would be provided to improve average crush load characteristics of the pellet. The pellet would then be coated with a low percent tensile elongation epoxy resin, having approximately 2 percent tensile elongation, to improve the ultimate strength of the reinforcement and provide good moisture resistance, thereby assuring retention of desirable strength charac¬ teristics. If the reinforcement is intended to be used in a high temperature environment, the resin selected for both the pellet and coating should be of a heat- -resistant type. In this way, a tough lightweight, high strength, heat and moisture-resistant reinforcement, having significant cost advantages, would be provided.

If an expandable resin coating is desired to provide an expansion of the adhesive resin coating in

the final cure step, the resin coating may include from 2 to 3 percent by resin weight of a blowing agent such as Celogen TSH, a trademark of Uniroyal, or it may in¬ clude from 6 to 10 percent by resin weight of unexpanded thermoplastic microspheres such as Expancel 55DU. The coating may be applied to the pellets at the rate of approximately 20 to 35 percent of the total pellet weight.

A coupling agent may be used in the resin or on the microbubbles to enhance the properties of the rein¬ forcement incorporating the pellets by increasing the tensile elongation and compressive strength. The coup¬ ling agent may be either a silane or non-silane coupling agent.

These pellets are utilized in a knee blocker assembly that is positioned in the area of the instrument panel of an automobile that is under the steering column forward of the knees. The construction of this assembly basically consists of a one-piece metal or plastic stamping which is approximately 30.5 cm high and is attached to the frame of the car, and which runs the full width of the car from hinge pillar to hinge pillar. The energy absorbing core is made by vacuum foaming a female pocket and inserting the cast pre- -coated pellets into the female pocket. These pellets will act as a crushable medium in that when the knee impacts the lower instrument panel, energy is absorbed by the pulverization and crush of the media. This energy absorbing core can be attached to the metal or plastic panel at a position below the steering column in front of the driver by a variety of methods. First, the pre-cast part can be locked or trapped into the sheet

metal or plastic at the top by a notch in the sheet metal or plastic. It can also be bonded to the metal or plastic stamping by means of a butyl type of adhesive. By a third means of attachment, the vacuum form sheet can be stapled to the metal or plastic stamping. When attached to the metal or plastic stamping, the outwardly facing side of the energy absorbing core is preferably covered with a 0.64-cm thick urethane foam with a vinyl skin attached thereto. The knee blocker is actually sandwiched between the metal or plastic stamping and the foam vinyl skin.

As shown in Figure 8, pellets as aforedescribed are incorporated into a knee blocker assembly 60 that is 5 under the steering column 62 forward of the knees of an individual. As shown in Figure 9, the knee blocker assembly 60 includes a one-piece metal or plastic stamp¬ ing 62 which is approximately 12 inches high and is attached to the frame of the car, and which runs the 0 full width of the car from hinge pillar 64a to hinge pillar 64b. An energy absorbing core 71 can be attached to the metal or plastic panel at a position below the steering column in front of the driver by a variety of _c _-> methods. The energy absorbing core is made by vacuum forming a female pocket and once this vacuum formed pocket is formed, casting the pre-coated pellets into the female pocket. The energy absorbing core is held then in a female tool heated to a temperature in the 0 range of from 93.3°C to 121.1°C until the core is cured. The core will cure completely within approximately 10 minutes using a water-based epoxy adhesive. When attached to the metal or plastic stamping, the outwardly facing side of the energy absorbing core is preferably covered with a 0.64-cm thick urethane foam padding 68

with a vinyl skin 70 attached thereto. The energy absorbing core 71 is actually sandwiched between the metal or plastic stamping 64 and the foam vinyl skin 70.

These pellets incorporated in the female pocket will act as a crushable medium in that when the knee impacts the lower instrument panel, energy is absorbed by the pulverization or crush of the medium. Such a system also provides for multi-directional energy absorption, and as such the knees may impinge upon the knee blocker at any orientation.

Furthermore, this pre-cast element can be attached to the metal or plastic panel for initial product assurance by means of a variety of methods. For example, the pre-cast part can be locked or trapped into the sheet metal or plastic at the top by a notch 74 in the sheet metal or plastic. It can also be bonded to the metal or plastic panel by means of a butyl tape 76 of adhesive. As a third means of attachment, the vacuum foam sheet can be stapled to the metal or plastic, such as 78. Other blockers or bolsters will have variations in the mechanical attachment, adhesive, or method of entrapment. For instance, fasteners could also be imbedded into the core to provide attachment. In addi¬ tion, a hole could be drilled through the core and a Christmas tree or plastic fastener could be plunged through the core and into the metal or plastic panel.

If dry coated pellets are to be supplied to the instrument panel fabricator, the vacuum formed piece, the adhesive, and the staple would be eliminated. For this application, a metal or plastic, cardboard or

plastic part would have to be provided to act as a closure wall to contain the pellets.

The sequence of manufacturing such a knee blocker is that the large metal or plastic stamping is produced first, the closure pieces fabricated and assembled to the main stamping, and the pellets are then poured or pumped loose into the cavity. The filled assembly is heated until the resin coating on the pellets cures. The multiple-fold advantage of the vacuum formed skin is that it acts as a forming tray. Since there will be 16 parts in the tool at one time, a package tray of the knee bolsters will be manufactured similar to a package tray for Christmas ornaments. Once the tray comes off the tool, it will be dye cut for approximately 80 percent of the perimeter around the bolster part. This tray of 16 parts will be shipped as a module in a carton. This vacuum formed skin helps improve the core performance by encapsulating the core on three sides. The vacuum formed material could be ABS, polystyrene, acetate, butyldiene, or other similar vacuum form materials. The thickness of the vacuum form is preferably between 0.051 to 0.318 cm. This dimension is important for a number of reasons. These include product performance, handling of the pre-cast part, and acting as a mold or tool in the casting process.

In another preferred embodiment of the knee bolster blocker of this invention, the pellets may be poured into position in the female cavity of the instrument panel. If this is done, the adhesive bead is not necessary. The vacuum formed skin would be removed and there would be a closure piece separating the formed vinyl from the pellet core. The closure piece could be

a polystyrene skin, metal or plastic stamping, welded in, or even stapled cardboard.

As aforedescribed, this knee blocker is engi¬ neered as a crushable system where the amount of crush and force to crush is controlled. The utilization of the pellets as described being inserted, into the female cavity of the knee bolster reduces the femur loads due to frontal impact at 48 kmh. This knee blocker can be tailored in thickness over the length of the part to control the amount of energy absorption required. Of course, this passive restraint could be applied to other areas of the automobile, such as the doors and/or dash¬ boards and would provide significant energy absorption capabilities.

It will be appreciated that the above examples and description of the preferred apparatus, process and compositions are intended as exemplary and not in a limiting sense. It will be appreciated that within the scope of the appended claims many variations, modifications and changes may be made within the spirit and scope within the present invention.

The following examples are given to illustrate the invention and should not be interpreted as limiting It in any way. Unless stated otherwise, all parts and percentages are given by weight.

Example 1

Interez Epi-Rez 504 (Bisphenol A) epoxy thermoset resin is intermixed and extruded with the following amounts of curing agent and microspheres:

Resin Weight

50 Interez Epicure 855 curing agent 23 3M C-15 glass microspheres

The extruded strand is cured for 2 minutes at 73.9°C, chopped into pellets, and coated with the following thermoset resin mixture:

% Resin Weight

100 Interez CMD 35201 thermoset resin 3.5 DiCyanimid catalyst

1 2-ethyl-4-methylimidazole

Example 2

Altek Polyester Molding Resin is intermixed and extruded with the following amounts of curing agent and microspheres:

% Resin Weight

22 3M C-15 glass microsphere bubbles 1 Noury Percadox 16 curing agent

(bis peroxydicarbonate)

The extruded strand is cured for 60 seconds at 96.1°C, chopped into pellets, and coated with the thermoset resin mixture described in Example 1.

Example 3

U.S.S. Chemical LB 804-31 Polyester resin is intermixed and extruded with the following amounts of curing agent and microspheres:

Resin Weight

25 3M C-15

0.25 MEK Peroxide

The extruded strand is cured for 60 seconds at 73.9°C, chopped into pellets, and coated with the thermoset resin mixture described in Example 1.

Example 4

Altek Polyester Molding Resin is intermixed and extruded with the following amounts of curing agent and microspheres:

% Resin Weight 5 Miralite 177 microspheres

1 Noury Percadox 16 curing agent

(bis peroxydicarbonate)

The extruded strand is cured for 60 seconds at 87.8°C, chopped into pellets, and coated with the thermoset resin mixture described in Example 1.

Example 5

U.S.S. Chemical LB 804-31 Polyester resin is intermixed and extruded with the following amounts of curing agent and microspheres:

Resin Weight

24 3M C-15 glass microsphere bubbles 5 Microlite 206 microspheres

2 Tert Butyl Peroxy (Noury) curing agent

The extruded strand is cured for 60 seconds at 121.1°C, chopped into pellets, and coated with the thermoset resin mixture described in Example 1.

Example 6

Interez Epoxy Epi-Rez 5071 Bisphenol A epoxy thermoset resin is intermixed and extruded with the following amounts of curing agent and microspheres:

% Resin Weight

25 Interez Epi-Cure 826 curing agent 30 Q-Cell 200 glass microspheres 0 The extruded strand is cured for 90 seconds at 90.5°C, chopped into pellets, and coated with the thermoset resin mixture described in Example 1.

_C - Example 7

U.S.S. Chemical LB 804-31 Polyester resin is intermixed and extruded with the following amounts of curing agent and microspheres:

% _Q Resin Weight

15 Dicaperl HP (10-30 microns) glass microspheres 3 Miralite 177 glass microspheres 2 Noury Percadox 16 curing agent 5 The extruded strand is cured for 90 seconds at 79.4°C, chopped into pellets, and coated with the thermoset resin mixture described in Example 1.

0

Example 8

U.S.S. Chemical MR 13031 Polyester resin is intermixed and extruded with the following amounts of curing agent and microspheres:

% Resin Weight

25 3M C-15 glass microspheres

2 Celogen TSH glass microspheres

2 Tert Butyl Peroxy (Noury) curing agent The extruded strand is cured for 60 seconds at 121.1°C, chopped into pellets, and coated with the thermoset resin mixture described in Example 1.

Example 9

Shell Epon 828 Bisphenol A epoxy thermoset resin is intermixed and extruded with the following amounts of thermoset resin, curing agent, and microspheres:

% Resin Weight

100 Shell Epon 1031 thermoset epoxy resin 20 Shell Epon 871 thermoset epoxy resin 110 3M C-15 glass microspheres

80 Nadic Methyl Anhydride curing agent 4 2-ethyl-4-methylimidazole

The extruded strand is cured for 90 seconds at 90.5°C, chopped into pellets, and coated with the thermoset resin mixture described in Example 1.

Example 10

Interez SU-2.5 polyfunctional thermoset resin is intermixed and extruded with the following amounts of thermoset resin, curing agent, and microspheres:

Resin Weight

25 Interez Epi-Rez 507 epoxy thermoset resin 70 Dicaperl HP (10-30 microns) glass microspheres 100 Nadic Methyl Anhydride curing agent 6 2-ethyl-4-methylimidazole

The extruded strand is cured for 90 seconds at 90.5°C, chopped into pellets, and coated with the thermoset resin mixture described in Example 1.

Example 11

U.S.S. Chemical 14059 Vinylester resin is intermixed and extruded with the following amounts of thermoset resin, curing agent, and microspheres:

%

Resin Weight

25 3M C-15 microspheres

2 Celogen TSH blowing agent 2 Tert Butyl Peroxy (Noury) catalyst

The extruded strand is cured for 120 seconds at 82.2°C, chopped into pellets, and coated with the thermoset resin mixture described in Example 1.

The ultimate strength and average crush load of blocks of pellets made according to the formulas of Examples 1 through 3 above have been tested against reinforcement blocks made of the prior art macrobubbles sold by 3M under the trade designation M35EX. As noted above, one of the most important characteristics of a reinforcement is its strength, which may be measured in terms of ultimate strength and average crush load.

Blocks of pellets made in accordance with Exam¬ ples 1 through 3 above and microbubbles were formed into separate cylindrical blocks having a diameter of 7.6 cm and a height of 7.6 cm. The blocks were formed of pellets coated with a two-part ambient-cured epoxy material and cast in a cylindrical mold. Each of the blocks was placed in a compression test machine having a machine speed of 1.27 cm per minute. The compression test machine has a maximum compression of 9,072 kg with the result being recorded in pounds compression over time on a chart recorder. The test results recorded included recording of crush load to 17-20 percent of the total height of the block.

The prior art control sample exhibited ultimate crush strength of 1,814 kg and an average crush load of approximately 1,361 kg.

Two different batches of pellets made in accordance with Example I were tested and both yielded considerably higher average crush load. The ultimate strength of the two batches differed with one batch having an ultimate strength of 2,903 kg and a second batch having an ultimate strength of 1,905 kg. The batch having the greater ultimate strength also had con¬ siderably better average crush load. The reason for the disparity between the two batches is that the batch hav¬ ing the lower ultimate strength and average crush load was made with resin that was more than one year old at the time it was formed into pellets.

Pellets made in accordance with Example 2 were formed into blocks and tested, yielding an ultimate strength measurement of 3,039 kg. The average crush

load of the block was slightly lower than the average crush load for the prior art block and the load over time decreased until it stabilized at approximately 907 kg.

The block made with pellets made according to Example 3 had an ultimate strength measurement of 1,814 kg and a lower average crush load than the control. The crush load characteristic was similar to that followed by the block made with pellets of Example 2.

In summary, the test results obtained with pellets made in accordance with Example 1 were markedly superior to those realized by the prior art in terms of both ultimate strength and average crush load. The ultimate strength was more than 50 percent greater than the control for pellets made in accordance with Examples 1 and 2. The average crush load for pellets made according to Example 1 in both batches was substantially superior to that of the test block made with the prior art 3M macrosphere material. The ability to control the ultimate strength and average crush load characteristics of reinforcements made with the pellets of the present invention presents the possibility of engineering rein¬ forcements to meet strength, weight and cost constraints depending upon the requirements of the particular rein¬ forcement.