Abstract: Light weight composites with high flexural strength comprise epoxy foam sandwiched between two layers of facing material have high strength and low weight and can be used to replace steel structures. The facing layer may be fibrous material especially glass or carbon fibres, the facing material is preferably embedded into the epoxy matrix. Alternatively they may be matching box structures or concentric metal tubes. The sandwich structures may be prepared by laying up the fibre; coating and/or impregnating the layer with epoxy resin, laying a layer of heat activatable foamable epoxy material, providing a further layer of the fibrous material optionally coated and/or impregnated with epoxy resin on the foamable material and heating to foam and cure the epoxy materials. Alternatively they may be formed by extrustion of the foamable material between the surface layers.

Abstract: A structural reinforcement for a hollow section at least part of at least one of whose surfaces is the internal surface of an external panel comprising a rigid reinforcing member having a shape that substantially conforms to the cross section to be reinforced. An expandable adhesive material is provided over a portion of the surface of the rigid reinforcing member and the shape of the rigid reinforcing member and the amount and location of the expandable adhesive is such that upon foaming the foam contacts and bonds to the internal surfaces of the hollow section other than the interior surface of the external panel. In this way deformation of the external body panel during the foaming and/or cooling of the foamed expandable material is reduced or prevented.

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: Parts are provided which combine structural reinforcement of hollow profiles and light weight means of attachment. Optionally, the part may also provide an acoustic baffle. The parts consists of a core coated with expandable structural reinforcing foam on at least part of its surface the core being provided with means for receipt of a nut and means to prevent rotation of the nut. Optionally, a piece of a second expandable material is provided on at least one extremity which can expand to fill the entire cross section of the hollow profile. In a preferred embodiment, the hollow profile is the A, B or C pillar of a vehicle and the nut is used for attaching doors.

Abstract: Laminar mouldings including a foamable material adhering to a moulded substrate are produced by providing a piece of foamable material within a mould and moulding the substrate within the mould at a temperature above the normal foaming temperature of the foamable material so that it adheres to the foamable material but does not cause it to foam. The moulding process may be injection moulding or blow moulding and the mouldings are useful as acoustic baffles or structural reinforcement for automobiles.

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.

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 hollow member to be reinforced with an expandable adhesive material over at least a portion of the surface of the structural reinforcement having one or more extensions on its external surface which control and direct the direction in which the adhesive material expands to bond the reinforcing member to the internal surface of the hollow member, some of the extensions also provide improved reinforcement.

Abstract: A method of reinforcing an automobile structure includes: providing an elongated hollow automotive frame structure; providing an elongated carrier having a longitudinal axis; applying a reinforcing medium to the carrier for forming a sleeve wherein the reinforcing medium is a heat activated expandable material; and inserting the sleeve in the hollow frame structure.

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.

Abstract: A structural reinforcement for a hollow section at least part of at least one of whose surfaces is the internal surface of an external panel comprising a rigid reinforcing member having a shape that substantially conforms to the cross section to be reinforced. An expandable adhesive material is provided over a portion of the surface of the rigid reinforcing member and the shape of the rigid reinforcing member and the amount and location of the expandable adhesive is such that upon foaming the foam contacts and bonds to the internal surfaces of the hollow section other than the interior surface of the external panel. In this way deformation of the external body panel during the foaming and/or cooling of the foamed expandable material is reduced or prevented.

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.

Abstract: Parts are provided which combine structural reinforcement of hollow profiles and light weight means of attachment. Optionally, the part may also provide an acoustic baffle. The parts consists of a core coated with expandable structural reinforcing foam on at least part of its surface the core being provided with means for receipt of a nut and means to prevent rotation of the nut. Optionally, a piece of a second expandable material is provided on at least one extremity which can expand to fill the entire cross section of the hollow profile. In a preferred embodiment, the hollow profile is the A, B or C pillar of a vehicle and the nut is used for attaching doors.

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.

Abstract: A reinforced sleeve including a carrier member and a reinforcing medium supported by the carrier member. The carrier is an elongated polymer member, and the reinforcing medium extends along at least a portion of the length of the carrier member. The reinforcing medium is preferably an epoxy-based resin. More particularly, the reinforcing medium is preferably a heat-activated structural foam.

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 reinforced sleeve including a carrier member and a reinforcing medium supported by the carrier member. The carrier is an elongated polymer member, and the reinforcing medium extends along at least a portion of the length of the carrier member. The reinforcing medium is preferably an epoxy-based resin. More particularly, the reinforcing medium is preferably a heat-activated structural foam.

Abstract: A reinforced sleeve including a carrier member and a reinforcing medium supported by the carrier member. The carrier is an elongated polymer member, and the reinforcing medium extends along at least a portion of the length of the carrier member. The reinforcing medium is preferably an epoxy-based resin. More particularly, the reinforcing medium is preferably a heat-activated 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 hollow member to be reinforced with an expandable adhesive material over at least a portion of the surface of the structural reinforcement having one or more extensions on its external surface which control and direct the direction in which the adhesive material expands to bond the reinforcing member to the internal surface of the hollow member, some of the extensions also provide improved reinforcement.

Abstract: A reinforced sleeve including a carrier member and a reinforcing medium supported by the carrier member. The carrier is an elongated polymer member, and the reinforcing medium extends along at least a portion of the length of the carrier member. The reinforcing medium is preferably an epoxy-based resin. More particularly, the reinforcing medium is preferably a heat-activated structural foam.

Abstract: A reinforced sleeve including a carrier member and a reinforcing medium supported by the carrier member. The carrier is an elongated polymer member, and the reinforcing medium extends along at least a portion of the length of the carrier member. The reinforcing medium is preferably an epoxy-based resin. More particularly, the reinforcing medium is preferably a heat-activated structural foam.