Abstract: A reinforcer for installation in a structural member is disclosed. The reinforcer includes a rigid carrier having at least a first surface and a second surface. The first surface is substantially orthogonal to said second surface. Bonding material is disposed both on said first surface and said second surface. The reinforcer is configured to be installed in a structural member such that the first surface is substantially parallel to a longitudinal axis of the structural member, and the second surface is substantially orthogonal to the longitudinal axis of the structural member.

Abstract: A baffle is provided that includes at least one carrier and a sealer disposed in a recess. When placed in a cavity, such as a vehicle cavity, sealer also expands into the cavity to seal the cavity. Baffle can be modified by including an insert within carrier to increase the weight, density, and structural rigidity of baffle, without altering the exterior dimensions of baffle. A baffle that includes an insert can be customized based on a particular application, without requiring time-consuming and expensive tooling changes.

Abstract: A structural reinforcement material is provided that includes a base material selected from thermosets, low viscosity thermoplastics with short transition phases and low viscosities, low melting point metallic alloys, and combinations thereof. At STP, the structural reinforcement material is a solid or a formable dough or a mixture thereof. When heated to an activation temperature, the structural reinforcement material becomes flowable into a cavity. Following cooling, the structural reinforcement material is a solid or a thermoset with a strength sufficient to reinforce the cavity. A structural reinforcement insert comprising the structural reinforcement material is also provided, as is a reinforced cavity of an automobile and a method of reinforcing a cavity.

Abstract: Exemplary reinforced structures, e.g., panel structures, and methods of making the same are disclosed. A reinforced structure may include a panel support extending along a panel. The panel support may be relatively rigid in comparison to the panel. The structure may further include an expandable support having a body portion mounted on the panel support. The body portion may be formed of an expandable material such that the body portion is configured to engage the panel upon expansion, thereby providing an expanded support acting between the panel and the panel support after expansion.

Abstract: An exemplary method of, for instance, forming a baffle or reinforcer includes extruding an expandable material to have a particular cross-sectional profile, inserting the expandable material into a molding tool, cutting the expandable material to a predetermined length within the molding tool, and overmolding a carrier material onto a portion of the expandable material within the molding tool.

Abstract: A baffle or reinforcer includes a carrier configured to be disposed in a cavity and a fixation mechanism disposed on the carrier and configured to at least partially support the carrier in the cavity. The fixation mechanism defines an opening for receiving an expandable material. The fixation mechanism has an anti-return device configured to prevent at least a portion of the expandable material from escaping through the opening during expansion. A method includes inserting the carrier into the cavity, injecting the expandable material into the cavity via the opening in the fixation mechanism, expanding the expandable material within the cavity, and preventing at least a portion of the expandable material from escaping through the opening during expansion.

Abstract: A structural member assembly includes a substantially hollow structural member and a structural reinforcer. The hollow structural member is formed by a plurality of panels. At least one of the panels includes a cut-out region extending from the edge of the panel to the interior of the panel so that the cut-out region is not fully enclosed by the panel. The structural reinforcer includes a rigid carrier and a bonding material. The structural reinforcer is installed in the interior of the structural member across said cut-out region.

Abstract: A method of forming a baffle or reinforcement comprises molding an expandable material in a first cavity of a mold and molding a carrier material onto the expandable material in a second cavity of the mold.

Abstract: A structural reinforcement material is provided that includes a base material selected from thermosets, low viscosity thermoplastics with short transition phases and low viscosities, low melting point metallic alloys, and combinations thereof. At STP, the structural reinforcement material is a solid or a formable dough or a mixture thereof. When heated to an activation temperature, the structural reinforcement material becomes flowable into a cavity. Following cooling, the structural reinforcement material is a solid or a thermoset with a strength sufficient to reinforce the cavity. A structural reinforcement insert comprising the structural reinforcement material is also provided, as is a reinforced cavity of an automobile and a method of reinforcing a cavity.

Abstract: A reinforcement including at least two separate members that are secured to each other. The reinforcement may further include a bonding material that is disposed on at least one of the members and confined within an outer perimeter of the carrier. The bonding material may be configured to secure the carrier to the structure. The two members are secured to each other to permit at least one of translational and rotational relative movement therebetween such that one of the members engages the bonding material, thereby forcing the bonding material beyond the outer perimeter of the carrier.

Abstract: A structural member includes one or more walls that define a cavity. A system for reinforcing the cavity includes a substantially rigid carrier configured to reside in the cavity. The carrier includes a pathway disposed in the carrier that provides an aperture between an exterior surface of the carrier and an interior surface of the carrier. An adhesive is disposed in a gap between at least a portion of the exterior surface of the carrier and the wall of the structural member. The adhesive is disposed proximate to the pathway.

Abstract: A reinforcement includes a carrier having a plurality of exterior walls spaced from one another. The carrier defines a channel extending substantially parallel to a longitudinal axis defined by a cavity. A material layer is disposed on at least one of the exterior walls within the channel such that an electrocoating material is able to flow through the channel before the material layer is expanded and the channel is substantially filled after the material layer is expanded.

Abstract: A reinforcer includes a carrier conforming generally to one or more inner walls of a cavity, and an adhesive arranged in one or more beads between the carrier and the one or more inner walls of the cavity, such that when the one or more adhesive beads is cured, the carrier is adhered to the one or more inner walls defining the cavity.

Abstract: Disclosed are various embodiments of a structural reinforcement system. The system reinforces hollow cavities within various products to increase the structural rigidity of the product. The system generally includes a rigid carrier, a bonding material, and an insert. The rigid carrier provides the primary structural reinforcement within the cavity, and also serves as a substrate to carry the bonding material. The insert is provided to increase the structural rigidity of the reinforcement system.

Abstract: A baffle is provided that includes at least one carrier and a sealer disposed in a recess. When placed in a cavity, such as a vehicle cavity, sealer also expands into the cavity to seal the cavity. Baffle can be modified by including an insert within carrier to increase the weight, density, and structural rigidity of baffle, without altering the exterior dimensions of baffle. A baffle that includes an insert can be customized based on a particular application, without requiring time-consuming and expensive tooling changes.

Abstract: A reinforcement includes a material layer disposed on a carrier that includes integrally formed support features, such as ribs, holes, pins, or a combination thereof, and/or a connector pin that deforms to secure the material layer to the carrier. The support features reduce the weak interface between the material layer and the carrier by improving bonding of the material layer to the carrier.

Abstract: A structural member assembly includes a substantially hollow structural member and a structural reinforcer. The hollow structural member is formed by a plurality of panels. At least one of the panels includes a cut-out region extending from the edge of the panel to the interior of the panel so that the cut-out region is not fully enclosed by the panel. The structural reinforcer includes a rigid carrier and a bonding material. The structural reinforcer is installed in the interior of the structural member across said cut-out region.

Abstract: A reinforcer for installation in a structural member is disclosed. The reinforcer includes a rigid carrier having at least a first surface and a second surface. The first surface is substantially orthogonal to said second surface. Bonding material is disposed both on said first surface and said second surface. The reinforcer is configured to be installed in a structural member such that the first surface is substantially parallel to a longitudinal axis of the structural member, and the second surface is substantially orthogonal to the longitudinal axis of the structural member.

Abstract: The present invention relates to an acoustic baffle device for sealing a cavity of a vehicle body at a predetermined cross section of the cavity, comprising a piece of sealing material that is formed in a shape corresponding to but being smaller than the shape of the cross section of the cavity. The acoustic baffle device of the invention is characterized in having a flap assembly having a lower neck defining a passage for a flexible tube or a similar device, said lower neck having a flap secured in closed position by a locking device and being connected preferably to the lower end of the lower neck through means that permit the reversible opening of the above-defined passage. Furthermore, the present invention relates to a flap assembly useful for such an acoustic baffle device, and to a process for sealing a cavity of a vehicle body at a predetermined cross section of the cavity.

Abstract: In the case of a reinforcing system for reinforcing a cavity of a structural element, a support element is connected to the structural element in the structural element for reinforcement purposes. The support element has channels, an adhesive is disposed in the cavity between the support element and the structural element, and the adhesive can be introduced into the cavity between the support element and the structural element by means of the channels.