Abstract: An epoxy/elastomer adduct, a method of forming the adduct and materials and articles incorporating the adduct are disclosed. The adduct preferably includes up to about 60% by weight of an elastomeric component, up to about 90% by weight of an epoxy component and optionally one or more additives.

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: 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: 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: 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: 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 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: There is disclosed a system and method of employing a porous container for sealing, baffling, reinforcing or a combination thereof. According to the method, a porous container having one or more openings is provided. An expandable material is associated with the container and is preferably placed within the container. Thereafter, the expandable material is expanded to contact and adhere to a structure of an article of manufacture (e.g., an automotive vehicle).

Abstract: There is disclosed a metallic foam and a method of forming a metallic foam such as an aluminum foam. There is also disclosed a method of using the metallic foam.

Abstract: A member is balanced by determining a target location at which weight is needed to counter an imbalance. A weighted adhesive is applied to the target location to then balance the member.

Abstract: The present invention relates to methods, materials, and products for forming a foamed product, comprising the steps of combining an epoxy-based component with an amine-based component. The epoxy component is cross-linked through a polymerization reaction catalyzed by the amine formulation. In this regard, an reactive mixture or exothermic reaction is created between the epoxy component and the amine component when combined. The heat generated by the exothermic reaction softens a thermoplastic shell of a blowing agent formulated within the epoxy component thereby enabling a solvent core within the thermoplastic shell of the blowing agent to expand from the heat generated by the exothermic or reactive mixture.

Abstract: There is disclosed a system and method of employing a porous container for sealing, baffling, reinforcing or a combination thereof. According to the method, a porous container having one or more openings is provided. An expandable material is associated with the container and is preferably placed within the container. Thereafter, the expandable material is expanded to contact and adhere to a structure of an article of manufacture (e.g., an automotive vehicle).

Abstract: The present invention relates to methods, materials, and products for forming a foamed product, comprising the steps of combining an epoxy-based component with an amine-based component. The epoxy component is cross-linked through a polymerization reaction catalyzed by the amine formulation. In this regard, a reactive mixture or exothermic reaction is created between the epoxy component and the amine component when combined. The heat generated by the exothermic reaction softens a thermoplastic shell of a blowing agent formulated within the epoxy component thereby enabling a solvent core within the thermoplastic shell of the blowing agent to expand from the heat generated by the exothermic reaction.

Abstract: There is disclosed a two-component adhesive material and method of use therefore. The two-component adhesive material is typically a cure-in-place adhesive that includes an amine component, an acid component, an epoxy component or a combination thereof.

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 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: A partition for forming a barrier in a channel has a molded resin-based plate and a plurality of thermally expandable pellets attached to one side of the plate. The partition is secured in place in the channel by mounting brackets. As heat is applied, a blowing agent in the pellets is activated and the pellets expand to many times their original volume. The resultant foam seals the gap between the plate and the surrounding structure and further secures the plate in place. The partition is particularly useful in forming a sound/water/air barrier in an automotive cavity.

Abstract: A partition for forming a barrier in a channel has a molded resin-based plate and a plurality of thermally expandable pellets attached to one side of the plate. The partition is secured in place in the channel by mounting brackets. As heat is applied, a blowing agent in the pellets is activated and the pellets expand to many times their original volume. The resultant foam seals the gap between the plate and the surrounding structure and further secures the plate in place. The partition is particularly useful in forming a sound/water/air barrier in an automotive cavity.

Abstract: A reinforced magnetic hot patch has an attached rigid backing. The hot patch expands and flows when heated to seal an opening in a structural member. A non-planar magnetic hot patch is also provided.

Abstract: A composition which cures and foams at room temperature contains a acid-catalyzed, polymerizable resin, an acid and a filler which liberates gas in an endothermic reaction with the acid. The acid serves the dual purpose of catalyzing the polymerization reaction and generating the foaming gas.