Structural foam

Abstract

A structural reinforcement for a hollow member comprising a rigid reinforcing member having a shape that substantially conforms to the cross section of the section of the hollow member to be reinforced with an expandable adhesive material over at least a portion of the surface of the rigid reinforcing member sufficient to bond the reinforcing member to at least two nonparallel internal surfaces of the structure.

1 - 24 . (canceled)  
   
   
       25 : A method of reinforcing a structure of an article of manufacture, the method comprising: 
 providing a rigid pre-formed structural reinforcing member formed of metal or plastic;    locating an unfoamed expansive adhesive material upon one or more surfaces of the structural reinforcing member; and    positioning the reinforcing member within a cavity of the structure of the article of manufacture such that the adhesive material approaches an internal surface of the structure;    activating the adhesive material to expand and adhere to the internal surface of the structure.    
   
   
       26 : A method as in  claim 25  wherein the structure of the article of manufacture is at least partially formed of aluminum.  
   
   
       27 : A method as in  claim 26  wherein the reinforcing member produces a sound deadening effect by blocking paths of in the cavity.  
   
   
       28 : A method as in  claim 27  wherein the article of manufacture is selected from a household appliance, an architectural structure, an automotive structure, an aerospace structure or a marine structure.  
   
   
       29 : A method as in  claim 25  wherein the structural reinforcing member further comprises at least one locator attached to and moulded with the structural reinforcing member, the at least one locator assisting in locating the member within the hollow structural member when said structural reinforcing member is placed within said structure prior to activation of said material.  
   
   
       30 : A method as in  claim 29  in which said at least one locator is a lug.  
   
   
       31 : A method as in  claim 25  wherein 
 i) the expandable material can be activated at a temperature of a curing step in an electrocoat process;    ii) the reinforcing member is an injection molded plastic and has a cellular, honeycomb or ribbed internal structure;    iii) the reinforcing member is made from filled polyamide in which the filler is selected from glass fibre or carbon fibre;    iv) the expandable adhesive material includes an epoxy-based resin;    v) the expandable material is applied over part of each of the top and bottom and the sides of the reinforcing member.    
   
   
       32 : A method as in  claim 25  wherein the reinforcing member is made from a thermosetting resin.  
   
   
       33 : A method as in  claim 25  wherein the expandable material expands at from 130° C. to 150° C.  
   
   
       34 : A method of reinforcing a structure of an automotive vehicle, the method comprising: 
 providing a rigid pre-formed structural reinforcing member, wherein including:    i) provision of the member includes forming the reinforcing member using a technique selected from injection moulding or extrusion;    locating an unfoamed expansive adhesive material upon one or more surfaces of the structural reinforcing member; and    positioning the reinforcing member within a cavity of the structure of the automotive vehicle such that the adhesive material approaches an internal surface of the structure;    activating the adhesive material to expand and adhere to the internal surface of the structure.    
   
   
       35 : A method as in  claim 34  wherein the reinforcing member assists in preventing point mobility, lozenging or both.  
   
   
       36 : A method as in  claim 34  wherein the structure includes a floor section at the base of a rear door pillar of the vehicle and the reinforcing member resists deformation of upward bending of the floor section in the event of a rear vehicle impact.  
   
   
       37 : A method as in  claim 34  wherein: 
 i) the expandable material can be activated at a temperature of a curing step in an electrocoat process;    ii) the reinforcing member is an injection molded plastic and has a cellular, honeycomb or ribbed internal structure;    iii) the reinforcing member is made from filled polyamide in which the filler is selected from glass fibre or carbon fibre;    iv) the expandable adhesive material includes an epoxy-based resin;    v) the expandable material is applied over part of each of the top and bottom and the sides of the reinforcing member.    
   
   
       38 : A method of reinforcing a hollow structure of an automotive vehicle, the method comprising: 
 providing a rigid plastic pre-formed structural reinforcing member, wherein:    i) providing the reinforcing member includes injection molding the reinforcing member to have a shape that substantially conforms to a cross-section of the hollow structure wherein the reinforcing member is formed to include holes suitable for drainage of water;    locating an unfoamed expansive adhesive material upon one or more surfaces of the structural reinforcing member, wherein:    i) location of the unfoamed expansive adhesive material upon the one or more surfaces is accomplished by a process selected from overmoulding, extrusion or two-shot injection moulding; and    positioning the reinforcing member within a cavity of the structure of the automotive vehicle such that the adhesive material approaches one or more internal surfaces of the structure, wherein:    i) the size of the reinforcing member including the expandable material is such that there is a clearance of not more than  1  cm between the reinforcing member and the one or more internal surfaces of the hollow structural member;    ii) the structure is a portion of the frame of the automotive vehicle;    applying an electrocoat to the structure including the one or more internal surface of the structure;    activating the adhesive material to expand and adhere to the one or more internal surfaces of the structure including:    i) bonding the reinforcing member to at least two non parallel internal surfaces of the structure.    
   
   
       39 : A method as in  claim 38  wherein the clearance is 3 to 10 millimeters.  
   
   
       40 : A method as in  claim 39  wherein the reinforcing member includes lugs molded as part of the reinforcing member.  
   
   
       41 : A method as in  claim 38  wherein reinforcing member assists in preventing point mobility, lozenging or both.  
   
   
       42 : A method as in  claim 38  wherein the structure includes a floor section at the base of a rear door pillar of the vehicle and the reinforcing member resists deformation of upward bending of the floor section in the event of a rear vehicle impact.  
   
   
       43 : A method as in  claim 42  wherein: 
 i) the expandable material can be activated at a temperature of a curing step in an electrocoat process;    ii) the reinforcing member is an injection molded plastic and has a cellular, honeycomb or ribbed internal structure;    iii) the reinforcing member is made from filled polyamide in which the filler is selected from glass fibre or carbon fibre;    iv) the expandable adhesive material includes an epoxy-based resin;    v) the expandable material is applied over part of each of the top and bottom and the sides of the reinforcing member.    
   
   
       44 : A method as in  claim 43  wherein the rigid injection molded plastic pre-formed structural reinforcing member extends along a length of the reinforcing member and wherein the reinforcing member comprises internal ribbing.