Metallic foam
There is disclosed a metallic foam and a method of forming a metallic foam such as an aluminum foam. There is also disclosed a method of using the metallic foam.
1 . A method of forming a metallic foam reinforcement of baffling member, the method comprising:
providing a plurality of metallic layers wherein the plurality of metallic layers includes at least three layers and wherein each of the metallic layers is aluminum based;
forming pre-cells between a first layer and a second layer of the at least three layers and between a second layer and a third layer of the at least three layers;
expanding each of the pre-cells into cells by a process selected from providing the pre-cells with compressed gas or expanding an expansion material within the pre-cells.
2 . A method as in claim 1 wherein each of the at least three layers has a thickness of at least about 0.1 mm but no greater than about 5 mm.
3 . A method as in claim 1 wherein the pre-cells are at least partially formed upon bonding the first layer to the second layer and the second layer to the third layer.
4 . A method as in claim 3 wherein the first layer is bonded to the second layer using a roll bonding technique.
5 . A method as in claim 1 wherein the pre-cells are expanded into cells by expanding the expansion material and wherein the expansion material expands at a temperature experienced during an automotive coating process step.
6 . A method as in claim 1 further comprising applying an expandable reinforcement baffling material to an exterior of the carrier member.
7 . A method as in claim 1 wherein the at least three layers include at least five layers.
8 . A method as in claim 1 wherein the pre-cells are formed by disposing masses of barrier material between the at least three layers.
9 . A method as in claim 1 further comprising forming connection portions between the pre-cells.
10 . A method of reinforcing or baffling a structure of an automotive vehicle, comprising:
forming a carrier member from metal foam;
disposing an expandable material upon the carrier member for forming a reinforcement member;
positioning the reinforcement member within a cavity of the structure of the automotive vehicle;
expanding and adhering the expandable material to walls of the structure wherein the walls at least partially define the cavity.
11 . A method as in claim 10 wherein the metal foam is aluminum based.
12 . A method as in claim 10 wherein the expandable material is a reinforcement material.
13 . A method as in claim 10 wherein the carrier member has a relatively thick outer skin.
14 . A method as in claim 10 wherein the carrier member includes a rib.
15 . A method as in claim 10 wherein the metal foam is formed of multiple layers each layer having a substantial amount of aluminum.
16 . A method as in claim 15 wherein the layers are bonded to each other using a roll-bonding technique.
17 . A method as in claim 10 wherein the carrier member includes either a rib or a relatively thick skin.
18 . A method of reinforcing a structure of an automotive vehicle, comprising:
providing a plurality of metallic layers wherein the plurality of layers includes at least three layers and wherein each of the metallic layers includes a substantial amount of aluminum;
forming pre-cells between a first layer and a second layer of the at least three layers and between a second layer and a third layer of the at least three layers;
expanding each of the pre-cells into cells by a process selected from providing the pre-cells with compressed gas or expanding an expansion material within the pre-cells for forming a carrier member;
disposing an expandable reinforcement material upon an exterior surface of the carrier member for forming a reinforcement member;
positioning the reinforcement member within a cavity of the structure of the automotive vehicle; and
expanding and adhering the expandable reinforcement material to walls of the structure wherein the walls at least partially define the cavity.
19 . A method as in claim 18 wherein the pre-cells are formed by disposing masses of barrier material between the at least three layers.
20 . A method as in claim 19 further comprising forming connection portions between the pre-cells.