Abstract: A reinforced hydroform member having an outer structural member reinforced by a structural foam supported by the outer structural member. The structural foam extends along at least a portion of the length of the outer structural member. The structural foam is a heat-activated epoxy-based resin. As the foam is heated, it expands and adheres to adjacent surfaces. The preferred structural foam material is commercially available from L&L Products of Romeo, Mich. under the designation L5206, L5207, L5208, or L5209.

Abstract: There is disclosed a process of forming reinforcements baffles and seals having malleable carriers. The process typically includes application of an activatable material to a malleable carrier and contouring of the activatable material the malleable carrier or both.

Abstract: A sound reduction system is provided. The system is preferably designed to allow air or other fluid to flow through the system while lessening the amount of sound flowing through the system.

Abstract: There is disclosed a method and assembly for locating a material adjacent or with a structure of an article of manufacture such as an automotive vehicle. The assembly typically includes a first compartment, a second compartment and a mixing initiator.

Abstract: There is disclosed a method of applying activatable material to a member of an article of manufacture such as an automotive vehicle. According the method, the activatable material is provided to an applicator followed by applying the activatable material to the member. Preferably, the activatable material is applied in a condition that makes the material suitable for allowing further processing or assembly of the member, the article of manufacture or both.

Abstract: A system and method for reinforcing at least a portion of a structural member, including at least one chamber or compartment having an interior portion which substantially conforms to the dimensions and geometry of the structural member being reinforced; and a reinforcement material for filling the interior portion of one or more of the compartments or chambers. The reinforcement material filling one or more of the compartments or chambers of the present invention can be a pumpable polymeric material, an heat activated expandable material, or a self-curing material. The compartment or chamber can be a polymeric material, such as nylon, which can be solid, blow-molded, flexible, or expandable depending upon the selected structural member to be reinforced.

Abstract: 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.

Abstract: There is disclosed a noise reduction member. Preferably, the noise reduction member is employed for sealing or baffling within a pillar or other structure of an automotive vehicle, although not required.

Abstract: A part for reinforcement of hollow structures comprises a series of segments flexibly interlinked to enable the part to be adjusted to fit structures of irregular cross section and direction, the segments contain foamable material which can be activated to fill the space between the parts and the hollow structure.

Abstract: A system and method for reinforcing at least a portion of a structural member, including at least one hollow carrier, having an exterior shell and an interior portion, which substantially conforms to the dimensions and geometry of the structural member being reinforced; and a lightweight, low density material for filling the interior portion of one or more of the carriers. The material filling one or more of the carriers of the present invention can be a reinforcement material, self-curing material, or a heat activated expandable material. The carrier can be produced by blow molding or rotational molding and has an adhesive material disposed along at least a portion of the exterior shell used to place, adhere, and affix the carrier to a targeted portion of the structural member selected to be structurally reinforced.

Abstract: The hollow profiles with inner reinforcement are especially suited for use in automobile bodies. The aim of the invention is to ensure that an anti-corrosion medium reaches all areas and to obtain rigidity in a hollow structure without increasing the weight of the profile or enlarging its cross-section. To this end, a solid core material is coated with an activable material and an outer panel is arranged in such a way as to form a hollow space which can be filled through the foaming action of the activable material. The size of this hollow space is determined by how the spacers are determined and by how the spacers are arranged, depending on the particular application. The solid core material consists of a foamed or non-foamed metallic material or of a synthetic material reinforced with metal fibers, carbon fibers or glass fibers.

Abstract: An activatable material and articles incorporating the same is disclosed. The activatable material includes at least three of an epoxy resin; a thermoplastic polyether; a blowing agent; a curing agent; and a filler. The activatable material is preferably used for sealing, baffling or reinforcing an article of manufacture such as an automotive vehicle.

Abstract: 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.

Abstract: A structural reinforcement member include a carrier member and a reinforcement material disposed upon the carrier member. The reinforcement member also includes at least one locating member. The reinforcement member has been found particularly useful for forming a structural system for articles of manufacture such as automotive vehicles.

Abstract: A lightweight member is provided for reinforcing, sealing or baffling structures of articles of manufacture such as automotive vehicles. The lightweight member preferably includes a carrier member having a cellular structure and an expandable material disposed thereon.

Abstract: A system and method for reinforcing at least a portion of a structural member, including at least one hollow carrier, having an exterior shell and an interior portion, which substantially conforms to the dimensions and geometry of the structural member being reinforced; and a lightweight, low density material for filling the interior portion of one or more of the carriers. The material filling one or more of the carriers of the present invention can be a reinforcement material, self-curing material, or a heat activated expandable material. The carrier can be produced by blow molding or rotational molding and has an adhesive material disposed along at least a portion of the exterior shell used to place, adhere, and affix the carrier to a targeted portion of the structural member selected to be structurally reinforced.

Abstract: The method of adhering members includes positioning of an adhesive material between an attachment surface of a first member (e.g., a door beam) and a second member (e.g., a bracket). Thereafter, the adhesive material is at least partially cured to adhere the material to the attachment surface to form an assembly and the assembly is assembled to an article of manufacture (e.g., an automotive vehicle).

Abstract: Methods and apparatuses are disclosed for applying melt flowable materials to components of articles of manufacture. The methods and apparatuses disclosed herein are concerned with formation of appropriate flowable materials, control over the manner in which the flowable materials are applied, treatment of the components prior to application of the flowable materials and the like. Moreover, the apparatuses and methods may be particularly suited for applying flowable materials to surfaces and components found in automotive, aerospace, and marine vehicles.

Abstract: Methods and apparatuses are disclosed for applying melt flowable materials to components of articles of manufacture. The methods and apparatuses disclosed herein are concerned with formation of appropriate flowable materials, control over the manner in which the flowable materials are applied, treatment of the components prior to application of the flowable materials and the like. Moreover, the apparatuses and methods may be particularly suited for applying flowable materials to surfaces and components found in automotive, aerospace, and marine vehicles.

Abstract: The method of adhering members includes positioning of an adhesive material between an attachment surface of a first member (e.g., a door beam) and a second member (e.g., a bracket). Thereafter, the adhesive material is at least partially cured to adhere the material to the attachment surface to form an assembly and the assembly is assembled to an article of manufacture (e.g., an automotive vehicle).