Locally reinforced hollow structural assembly

Abstract

A reinforced structural assembly is provided including a hollow structure having a cavity with a hole. A bag is inserted into the cavity and has an end with an opening extending out of the cavity through the hole. A device injects a structural foam into the bag. The bag is closed and the end of the bag is inserted into the cavity. A cap is installed over the hole. The foam expands to fill the cavity but is contained within the bag thereby providing localized reinforcement in the desired area.

1 . A method of locally reinforcing a hollow structure to support a component comprising the steps of: 
 (a) inserting a bag into a cavity of a structure;    (b) filling the bag with a material;    (c) expanding the material to provide a localized reinforcement area within the structure; and    (d) supporting a component on the structure at the localized reinforcement area.    
   
   
       2 . The method according to  claim 1 , wherein the material is a structural foam.  
   
   
       3 . The method according to  claim 1 , wherein the bag is closed prior to step (c).  
   
   
       4 . The method according to  claim 1 , wherein an end of the bag is closed and inserted into the cavity after step (b) and prior to step (c).  
   
   
       5 . The method according to  claim 1 , wherein step (a) includes inserting the bag through a hole in the structure and including installing a cap into the hole subsequent to step (b).  
   
   
       6 . The method according to  claim 5 , wherein step (d) includes positioning the component to at least partially overlap the hole.  
   
   
       7 . The method according to  claim 5 , including providing the cap with a first locating feature, and providing the component with a second locating feature wherein the first and second locating features cooperate to locate the component relative to the structure.  
   
   
       8 . The method according to  claim 7 , wherein the structure comprises a hollow axle and the component comprises a suspension component.  
   
   
       9 . A method of locally reinforcing a hollow structure to support a component comprising the steps of: 
 (a) inserting a bag through a hole in a hollow structure that defines a cavity;    (b) filling the bag with a structural foam;    (c) installing a cap in the hole; and    (d) expanding the structural foam to provide a localized reinforcement area within the hollow structure.    
   
   
       10 . The method according to  claim 9 , wherein step (b) includes closing an end of the bag and inserting the bag into the cavity through the hole, performing step (c) subsequent to step (b), and performing step (d) subsequent to step (c).  
   
   
       11 . The method according to  claim 9 , including supporting a component on the hollow structure at the localized reinforcement area.  
   
   
       12 . The method according to  claim 11 , including providing the cap with a first locating feature, and providing the component with a second locating feature wherein the first and second locating features cooperate to locate the component relative to the structure.  
   
   
       13 . The method according to  claim 11 , wherein the hollow structure comprises a hollow axle and wherein the component comprises a suspension component.  
   
   
       14 . A reinforced structural member comprising: 
 a structure having a cavity, said structure including a hole in communication with said cavity;    a bag insertable through said hole and disposed within said cavity, said bag defining a space;    a structural foam disposed within said bag and filling said space to provide a localized reinforcement area in said structure; and    a cap that covers said hole.    
   
   
       15 . The reinforced structural member according to  claim 14  wherein said bag includes an end having an opening that facilitates insertion of said structural foam into said bag, said end being disposed within said cavity when said cap covers said hole.  
   
   
       16 . The reinforced structural member according to  claim 14 , including a component mounted on said structure at said localized reinforcement area.  
   
   
       17 . The reinforced structural member according to  claim 16 , wherein said component at least partially overlaps said hole.  
   
   
       18 . The reinforced structural member according to  claim 16 , wherein said cap includes a first locating feature and said component includes a second locating feature that cooperates with said first locating feature to position said component relative to said structure.  
   
   
       19 . The reinforced structural member according to  claim 18 , wherein said component comprises a suspension component and said structure comprises a hollow axle.