An automotive vehicle frame reinforcement system has a skeleton member designed to be secured to a vehicle frame, such as a roof or pillar section. An expandable material, such as an epoxy-based reinforcing foam, is disposed on the skeleton member. Once the system is attached to the frame, the foam expands and cures during an automobile assembly operation, bonding the reinforcement system to the frame. As a result, the reinforcement system provides enhanced load distribution over the vehicle frame without adding excessive weight.

Structural reinforcement system for automotive vehicles

An energy management system and device for use in an automotive frame, rail, or other structural component of an automotive vehicle. The frame or rail having a cavity or exposed surface capable of supporting at least one member. The member having an interior portion and an exterior portion with the interior portion being defined by at least one trigger or step change to the geometry of the inner portion to target and direct axial bending of the system. A reinforcing material, such as a polymer-based expandable material, is disposed along the exterior portion of a member prior to final assembly of the vehicle by the vehicle manufacturer. The system is activated as the vehicle undergoes the final vehicle assembly process and paint operation which activates and transforms the reinforcing material to expand, bond and structurally adhere the frame rail to mange, direct, and/or absorb energy in the event of an impact to the vehicle from an applied load or an external force.

Automotive rail/frame energy management system

An structural reinforcement system for use with hydroforms and other closed forms having a plurality of members designed to be secured to a closed form, such as an hydroform tube used in automotive applications. A bonding material, such as an epoxy-based reinforcing foam, is disposed on at least a portion of the outer surface of each of the plurality of members. Once the system is attached to the closed form, the foam expands and cures during an automobile assembly operation, bonding the reinforcement system to the hydroform tube and the members. As a result, the reinforcement system provides enhanced load distribution over the vehicle frame without adding excessive weight and further serves to reduce noise and vibrational characteristics of the automotive vehicle.

Hydroform structural reinforcement system

A part having a non-planar wall is reinforced using a preform laminate having a shape which conforms to the non-planar wall The preform laminate is comprised of a foil or sheet carrier (32) and an outer layer of an unexpanded foam forming resin layer (30), which is inserted against the part with the resin layer disposed toward the non-planar wall The resin layer is cured and expanded by application of heat to form a structural reinforcing foam

Reinforced channel-shaped structural member methods

The present invention is directed to an expandable pre-formed plug (10) that is suitable for sealing and/or structurally reinforcing a structure member (20) having surfaces defining a space therebetween. The plug (10) is comprised of at least an expandable inner core (12) having an outer surface and a transportable outer skin (14) that preferably substantially encapsulates the core (12). In a preferred embodiment, the shape of the unexpanded plug (10) is designed to mate with the surfaces that define a space therebetween upon expansion. The adhesive skin (14) is generally dry to the touch at room temperature, however, upon initiation of expansion, the inner core expands and the surrounding skin (14) is displaced in a coordinated manner. After some period of expansion, the outer skin (14) preferably durably adheres or bonds to the walls (22) of the surfaces defining a space therebetween and the outer surface of the core (12). A method for using such a plug (10) is also disclosed.

Expandable pre-formed plug

A partition for forming a barrier in a channel has a molded resin-based plate and a plurality of thermally expandable pellets attached to one side of the plate. The partition is secured in place in the channel by mounting brackets. As heat is applied, a blowing agent in the pellets is activated and the pellets expand to many times their original volume. The resultant foam seals the gap between the plate and the surrounding structure and further secures the plate in place. The partition is particularly useful in forming a sound/water/air barrier in an automotive cavity.

Self-sealing partition

A reinforced magnetic hot patch has an attached rigid backing. The hot patch expands and flows when heated to seal an opening in a structural member. A non-planar magnetic hot patch is also provided.

Magnetized hot melt adhesive articles

A bladder system and method for reinforcing at least a portion of a structural member, including a flexible barrier member for dividing at least a portion of the structural member being reinforced into one or more sections; and a reinforcement material for filling one or more sections bounded by the flexible barrier member. The reinforcement material filling one or more sections of the structural member can be a pumpable polymeric material, and the flexible barrier member can be a polymeric material.

Bladder system for reinforcing a portion of a longitudinal structure

A hollow molded-to-shape expandable sealer is molded in a blow molding or rotational molding process which can be installed in a body cavity and then expanded to fill the cavity during an electro-coat or paint drying or curing process in order to block any air and moisture penetration into the body cavity.

Michael J. Czaplicki

Papers

Structural reinforcement system for automotive vehicles

Self-sealing partition

Magnetized hot melt adhesive articles

Bladder system for reinforcing a portion of a longitudinal structure

Hollow molded-to-shape expandable sealer