Abstract: A structural member having at least two non-coplanar surfaces is reinforced by providing a drop in insert between the surfaces. The insert is a carrier having an expandable structural foam intimately bonded to the carrier. When the foam is expanded, the foam becomes intimately bonded to the surfaces of the structural member to reinforce the structural member.

Abstract: A tri-laminate body panel stiffener includes two polymer layers with or without a backing. One of the layers is a compliant foam layer mounted against a substrate while the other layer is a rigid foam layer mounted against the compliant foam layer. In another aspect of the invention the laminate comprises a backing member having an expandable foam mounted thereto with two or more opposing edges of the laminate being of non-straight construction such as being wavy or saw tooth. A pattern of holes may be formed through the foam and backing layers.

Abstract: A reinforced beam has an internal I-beam structure with opposed adhesive foam layers. The foam layers are extruded, cut to length and placed on opposed surfaces of the I-beam. When the reinforced beam is heated. The adhesive layers expand to secure the I-beam in place.

Abstract: A tri-laminate body panel stiffener includes two polymer layers with or without a backing. One of the layers is a compliant foam layer mounted against a substrate while the other layer is a rigid foam layer mounted against the compliant foam layer. In another aspect of the invention the laminate comprises a backing member having an expandable foam mounted thereto with two or more opposing edges of the laminate being of non-straight construction such as being wavy or saw tooth. A pattern of holes may be formed through the foam and backing layers.

Abstract: A reinforced beam has an internal I-beam structure with opposed adhesive foam layers. The foam layers are extruded, cut to length and placed on opposed surfaces of the I-beam. When the reinforced beam is heated. The adhesive layers expand to secure the I-beam in place.

Abstract: The joint reinforcement member for a hollow structure of an automotive vehicle has a carrier portion with an outer surface. The carrier portion has a base portion with a first extension having a first longitudinal axis and a second extension having a second longitudinal axis. The first longitudinal axis and second longitudinal axis correspond to the hollow structure. A thermally expandable adhesive layer is disposed on the outer surface of the carrier portion and substantially covers the outer surface. A method for forming the joint member includes providing a carrier having a plurality extensions extending from a base portion that correspond to the hollow structure a layer of thermally expandable adhesive materials applied to the carrier portion. The carrier portion is heated to activate the adhesive layer. The adhesive layer is cooled so that the adhesive layer is bonded to the structural member.

Abstract: A channel-shaped section has a thin, local reinforcement shell separated from the channel-shaped section by a layer of structural foam. At the reinforced section an arch geometry is utilized which extends in a direction opposite that of the force to which the member is subjected. The arch may be present as the channel-shaped member, the reinforcement shell or both the channel-shaped member and the shell. A portion of the shell contacts the channel-shaped member and is attached thereto by welding or other means of attachment.

Abstract: A laminate reinforced beam assembly includes a beam having a channel shape defined by spaced side walls. The beam has a contact location where it would be subjected to a point loaded force. A reinforcement layer is provided on each of the side walls. The reinforcement layer is made of a polymer which forms a structural foam in its cured condition and which has a shape wherein its side edges taper toward each other in a direction away from the contact location.

Abstract: A three-dimensional laminate beam is formed by inserting a preformed foam core insert within a hydra-formed metal section having curved three-dimensional geometry. A reinforcing polymer is pumped in and around the foam core insert so as to be adjacent the inside wall of the shell. The polymer bonds to the inside wall of the shell upon the polymer being cured.

Abstract: A reinforced structural member has a channel-shaped laminate structure of a metal stamping, a channel-shaped foil and an intervening layer of structural foam. The reinforced structural member is formed by pressing a foil/resin preform into a channel and thermally expanding the resin to form a structural foam.

Abstract: A hollow reinforced structural member has a bulkhead having a layer of thermally expanded resin disposed between opposed side walls. A sleeve is retained within the resin layer and is oriented perpendicular to the longitudinal axis of the reinforce structural member. The sleeve is an alignment with bolt holes in opposite sides of the reinforced structure such that a bolt can be inserted there through. A component can then be bolted to the reinforced structural member at the site of the reinforcement. The invention not only increases the strength of the part, but also reduces vibration and noise transmission.

Abstract: A method for reinforcing a selected portion of a structural part utilizes a flexible tube having a unexpanded, preferably thermally expandable resin sheath. The sheath may be limited to a selected region along the length of the flexible tube. The flexible tube is inserted through a curved passage and conforms to the geometry of the part to be reinforced. After the portion of the tube having the sheath reaches the desired location, the tube is secured in place. Upon heating, the resin expands to several times its original volume and fills the structural cavity only at that region.

Abstract: A stiffener is provided for reinforcing a hollow structure having a pair of spaced walls. The stiffener includes a carrier member with a layer of expandable polymer which creates a structural foam when the polymer is later expanded. The stiffener could comprise a single laminate shaped to fit in the appropriate locations of the hollow structure so that when the polymer is expanded it forms a structural foam intimately bonded to the pair of spaced walls. The stiffener may also be in the form of a corrugated frame wherein individual laminates are provided with notches to permit the individual laminates to be interlocked with each other at the notches.

Abstract: A laminate support beam includes an outer structural member which has a channel shape with a longitudinal rigid inner member precoated with structural foam to form a drop-in insert unit which is dropped into the channel of the outer structural member when the structural foam is heat expandable to intimately bond to the inner surface of the outer member and provide a lightweight reinforcement for the outer member.

Abstract: A hollow structural member is reinforced by a housing in the form of a framework exposed structural foam on the housing. The housing is placed in the structural member at an orientation with its longitudinal axis perpendicular to the longitudinal axis of the structural member so that the foam is disposed directly against opposed walls of the structural member. Upon curing the foam becomes intimately bonded to the opposed walls of the structural member and to the housing for reinforcing the structural member. Preferably the housing is formed by extrusion so that it can be cut to size across its extrusion axis.

Abstract: A stiffener is provided for reinforcing a hollow structure having a pair of spaced walls. The stiffener includes a carrier member with a layer of expandable polymer which creates a structural foam when the polymer is later expanded. The stiffener could comprise a single laminate shaped to fit in the appropriate locations of the hollow structure so that when the polymer is expanded it forms a structural foam intimately bonded to the pair of spaced walls. The stiffener may also be in the form of a corrugated frame wherein individual laminates are provided with notches to permit the individual laminates to be interlocked with each other at the notches.

Abstract: A channel-shaped section has a thin, local reinforcement shell separated from the channel-shaped section by a layer of structural foam. At the reinforced section an arch geometry is utilized which extends in a direction opposite that of the force to which the member is subjected. The arch may be present as the channel-shaped member, the reinforcement shell or both the channel-shaped member and the shell. A portion of the shell contacts the channel-shaped member and is attached thereto by welding or other means of attachment.

Abstract: A laminate for reinforcing a structural member having a plurality of side walls comprises a carrier having at least one inclined support surface. Each support surface has an outer edge disposed toward a respective side wall. A layer of extruded uncured structural foam is on each support surface and terminates inwardly of the outer edge. The foam expands when cured and tumbles down the inclined support surface of the carrier to become bonded to the side wall as well as the carrier. By being spaced from the outer edge of the support surface, the tendency for the foam to wipe against the side wall is minimized as is the tendency for a worker to touch the foam when the worker places the carrier into the structural member.

Abstract: A laminate bulkhead comprises an expandable polymer sandwiched between two stiff members which are of a structure so that the expandable polymer is flared out or thicker in the area or along the line where the polymer expands and is bonded to the walls of a hollow structure in which the bulkhead is placed. The direction of expansion of the polymer results from the polymer being constrained by the stiff members on either side of the expanding polymer.

Abstract: The joint reinforcement member for a hollow structure of an automotive vehicle has a carrier portion with an outer surface. The carrier portion has a base portion with a first extension having a first longitudinal axis and a second extension having a second longitudinal axis. The first longitudinal axis and second longitudinal axis correspond to the hollow structure. A thermally expandable adhesive layer is disposed on the outer surface of the carrier portion and substantially covers the outer surface. A method for forming the joint member includes providing a carrier having a plurality extensions extending from a base portion that correspond to the hollow structure a layer of thermally expandable adhesive materials applied to the carrier portion. The carrier portion is heated to activate the adhesive layer. The adhesive layer is cooled so that the adhesive layer is bonded to the structural member.