Member for reinforcing, sealing or baffling and reinforcement system formed therewith

Abstract

A member is provided for reinforcing, sealing or baffling structures of articles of manufacture such as automotive vehicles. The member typically includes a carrier member that is typically at least partially formed of a metal. The member also typically includes an expandable material disposed on the carrier member.

Description

CLAIM OF PRIORITY

To the extent applicable, the present invention claims the benefit of the priority of U.S. Provisional Application Ser. No. 60/623,099, filed Oct. 28, 2004, the contents of which are incorporated by reference herein.

TECHNICAL FIELD

The present invention relates to a member, which is employed for providing reinforcing, sealing, baffling, combinations thereof or the like to a structure of an article of manufacture such as an automotive vehicle. More particularly, the present invention relates to a reinforcement member that is at least partially formed of a metal or polymeric foam (e.g., includes an aluminum foam carrier) or a solid metal or metal alloy.

BACKGROUND

For many years, industries such as the transportation industry have been innovatively designing members for enhancing structural reinforcement, damping, sealing, baffling, thermal insulation and acoustic absorption characteristics of articles such as furniture, buildings and transportation vehicles (e.g., automotive vehicles, boats, trains, busses, airplanes or the like). Design of such members can involve several different considerations, and these considerations may need to be balanced against one another to achieve a desired result. Examples of such considerations include, without limitation, strength, stiffness, weight, and cost of the members. Other considerations include compatibility of the members with articles of manufacture, ease of assembling the members to articles of manufacture, ability of the members to provide desired levels of damping, reinforcement or sealing or other like considerations.

In the interest of continuing such innovation, the present invention provides an improved member suitable for providing baffling, sealing, reinforcing, a combination thereof or the like to a structure of an article of manufacture.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a perspective view of an exemplary reinforcement member formed in accordance with an aspect of the present invention.

FIG. 2 illustrates a sectional view of the exemplary reinforcement member taken along line 2-2.

FIG. 3 illustrates an exemplary application of the reinforcement member of FIG. 1 to a structure of an automotive vehicle in accordance with an aspect of the present invention.

SUMMARY OF THE INVENTION

A process is employed for reinforcing, sealing or baffling a structure (e.g., a pillar) of an article of manufacture (e.g., an automotive vehicle). The process typically includes formation of a metal material into a carrier. Such formation typically includes a thixomolding process, although not required. Preferably the metal material includes aluminum, magnesium or a combination thereof. An expandable material is often applied to the carrier to form a member for reinforcement, baffling or sealing. The member is then typically inserted within a cavity of the structure of the article of manufacture. Thereafter, the expandable material may be activated to expand, contact and wet internal walls of the cavity of the structure of the article of manufacture and cured and adhered top the walls of the structure.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is predicated upon the provision of an improved member for sealing, baffling or reinforcing a structure of an article of manufacture. The present invention also provides a method of making the improved member, a method of using the improved member and a system formed thereby. Although it is contemplated that the member may be employed in a variety of articles of manufacture, for exemplary purposes, the member is discussed herein as being employed in an automotive vehicle. The process for forming the member and for applying the member to an automotive vehicle preferably includes one or a combination of the following steps:

• • i) providing a metal or polymeric material such as aluminum, aluminum alloy, aluminum based metal matrix composite, magnesium, magnesium alloy, nylon, combinations thereof or the like typically in a molten or partially molten state;
  • ii) shaping (e.g., extruding, casting or molding) the metal material to form a carrier member wherein the carrier member can have an internal cellular structure or can be internally solid and continuous;
  • iii) applying an expandable material to a surface of the carrier member for forming the member, typically a reinforcement member;
  • iv) placing the member within a cavity of an automotive vehicle, the cavity being defined by one or more walls of a structure of the automotive vehicle; and
  • v) activating the expandable material to form a structural foam that is adhered to the carrier member and the one or more walls of the structure of the automotive vehicle for forming a reinforced structural system.

For exemplary purposes, FIGS. 1 and 2 illustrate a reinforcement member 10 formed in accordance with an aspect of the present invention. The reinforcement member 10 includes a carrier member 12 and an expandable material 14 disposed upon the carrier member 12.

Material for the Carrier Member

The carrier member is typically formed of a metal material, which may include any metal such as tin, steel, aluminum, magnesium, iron, nickel, copper, cobalt, titanium, Nb, vanadium, zirconium, tungsten, a combination thereof or the like. The carrier member may also be formed of a polymeric material such as polyamide (e.g., nylon). The metal material or the polymeric material may also include a variety of additional materials such as fillers, fibers, metal matrix composite (MMC), refractory particles, stabilizers, combinations thereof or the like. Typically, when metal is employed, the metal material for the carrier member is at least 70% metal, more typically at least 85% metal and even more typically at least 92% metal. In a preferred embodiment, the metal material is at least 65% aluminum and/or magnesium, more typically at least 80% aluminum and/or magnesium and even more typically at least 90% aluminum and/or magnesium.

As used herein, specification of a metal will typically include that metal as well as alloys of that metal, unless otherwise specifically stated. For example, specification of aluminum is meant to include pure aluminum and aluminum alloys, unless otherwise stated.

Casting or Molding the Metal Material into the Carrier Member

It is contemplated that the carrier member may be formed, shaped or both according to a variety of techniques such as molding, casting, extruding, stamping, combinations thereof or the like.

Typically, the carrier member can be shaped to have nearly any desired external surface shape and can also be internally shaped for example by using inserts, which may be removable or non-removable. For exemplary purposes, the carrier member 12 of FIGS. 1 and 2 has been formed to have an external surface 20 that defines a first concave arcuate surface 22 and a second concave arcuate surface 24. Moreover, the external surface 20 includes multiple cavities 28 for receiving the expandable material 14.

In one embodiment, a metal (e.g., an aluminum) foamed carrier is formed according to a process. The process typically includes a combination of the following steps:

• • i) combining of a particulate foaming agent with a particulate metal or metal alloy to form a foaming agent/metal admixture;
  • ii) forming masses of the admixture; and
  • iii) molding the masses of the admixture to activate the foaming agent and form a cellular carrier of a desired shape.

Typically the metal (e.g., steel, aluminum or aluminum alloy or other metal) is mixed with the foaming agent (e.g., titanium hydride) to form a substantially well mixed or homogeneous metal/foaming agent admixture. Such mixing can be accomplished by supplying the metal and the foaming agent and potentially other ingredients (e.g., steel ball bearings) to a container or bin and mixing these components with a mixing device such as an impeller to form the admixture.

Once formed, the metal/foaming agent admixture is typically further processed to form several masses (i.e., solid or semi-solid masses) of the admixture. As one example, the admixture may be extruded under pressure to form masses (e.g., bars, plate or panel) of the admixture. As another example, the admixture may be roll bonded between metal sheets such as aluminum or steel sheets to form masses (e.g., sandwich structures) with the admixture held between the sheets.

The masses can then be molded and the foaming agent activated to form a cellular or foamed carrier of a desired shape. Typically, the masses of the metal/foaming agent admixture are placed within a mold or die having the desired shape of the carrier. Thereafter, the admixture is heated (e.g., in an oven or furnace) to a temperature that at least partially or substantially entirely melts or softens the metal of the admixture and, at the same time or at different times, activates the foaming agent (e.g., TiH) to form gas bubbles (e.g., H₂ bubbles) that become entrapped within the metal thereby forming a cellular carrier of the desired shape.

It is contemplated that a skin may be formed on the outer periphery of the carrier using any forming techniques described herein by controlling the cooling of the metal foam within a mold or using one of the other techniques described herein or elsewhere.

In other embodiments, it is contemplated that the carrier member may be formed of an internally continuous, solid and/or non-cellular material. In one exemplary embodiment, a metal may be die cast to form the carrier member to the desired shaped. In such an embodiment, a metal such as aluminum or magnesium is typically provided in a molten state to a die that has a shape corresponding to the desired shape of the carrier member. Thereafter, the metal is allowed to cool within the die to form a solid metal carrier.

In another embodiment, an internally solid or continuous carrier member is formed using a thixomolding process. According to the process, metal masses (e.g., chips, pellets or the like) are feed to a machine having a molding barrel and a screw. The screw of the machine then advances the masses (e.g., by rotation of the screw) and the masses are at least partially softened or melted to form a metal liquid or semi-solid fluid (e.g., a slurry, a liquid, a mixture of liquid and solid or the like). In one particular embodiment, the masses are formed into a slurry of spherical or otherwise shaped solid particles in a liquid metal matrix. Although, the spherical or otherwise solid particles are typically internally solid, it is contemplated that the spherical or otherwise shaped solid particles may be hollow for forming a cellular carrier member.

Once formed, the metal fluid is fed to or injected within a cavity of a mold at a temperature of between about 150-400° C. and more typically between about 200-250° C., although higher or lower temperatures may be employed depending upon the metal or metal mixture being shaped. Typically, the cavity is in the desired shape of the carrier member. The metal fluid then solidifies to form a carrier member in a desired shape and/or configuration.

Generally, thixomolding processes, materials for thixomolding, thixomolding equipment and the like are disclosed in U.S. Pat. Nos. 6,736,188; 6,514,309; 6,514,308; 6,299,665; 6,059,012; 5,996,679; 5,983,978; 5,819,839; 5,711,366; all of which are incorporated herein by reference for all purposes.

In yet another embodiment, it is contemplated that a polymer material may be injection molded or otherwise molded to form a solid or cellular carrier member of desired shape. One exemplary method of forming a cellular polymeric carrier is disclosed in copending application serial no. 10/686,845, filed October 16, 2003, which is incorporated herein by reference for all purposes.

Generally it is contemplated that the outer surface of the carrier may include or be roughened or textured for allowing the expandable material to adhere to the surface with greater strength. In one embodiment, the die or mold may be roughened or textured such that the carrier, the skin or both having a corresponding roughness or texture upon formation of the carrier. In another embodiment, the carrier may be formed or shaped and the outer surface may be subsequently roughened (e.g., by sanding or other technique).

Applying Expandable Material to the Carrier Member to Form a Reinforcement Member

When used in automotive vehicles or other articles of manufacture, it is preferable for an expandable material to be applied to the carrier member of the invention for forming a reinforcement member or a member for sealing or baffling. In FIGS. 1 and 2, the expandable material 14 is disposed upon the outer surface 20 of the carrier member 12 for forming the reinforcement member 10. In particular, the expandable material 14 is at least partially disposed within the cavities 28 formed in the carrier member 12. It is contemplated, however, that the expandable material may be placed in nearly any configuration upon any surface of any carrier member formed in accordance with the present invention.

The expandable material may be formed of several different materials. Generally speaking, the member may utilize technology and processes for the forming and applying the expandable material such as those disclosed in U.S. Pat. Nos. 4,922,596, 4,978,562, 5,124,186, and 5,884,960 and commonly owned, co-pending U.S. application Ser. No. 09/502,686 filed Feb. 11, 2000 and U.S. applicaiton Ser. No. 09/524,961 filed Mar. 14, 2000, and U.S. Application attorney docket no. 1001-141, filed Jun. 15, 2004, all of which are expressly incorporated by reference for all purposes. Typically, when used for reinforcement, the expandable material is formed of a high compressive strength and stiffness heat activated reinforcement material having foamable characteristics. The material may be generally dry to the touch or tacky and can be placed upon the carrier member or the like in any form of desired pattern, placement, or thickness, but is preferably of substantially uniform thickness. One exemplary expandable material is L-5204 structural foam available through L&L Products, Inc. of Romeo, Mich.

Though other heat-activated materials are possible for the expandable material, a preferred heat activated material is an expandable polymer or plastic, and preferably one that is foamable. A particularly preferred material is an epoxy-based structural foam. For example, and without limitation, the structural foam may be an epoxy-based material, including an ethylene copolymer or terpolymer that may possess an alpha-olefin. As a copolymer or terpolymer, the polymer is composed of two or three different monomers, i.e., small molecules with high chemical reactivity that are capable of linking up with similar molecules.

A number of epoxy-based structural reinforcing or sealing foams are known in the art and may also be used to produce the structural foam. A typical structural foam includes a polymeric base material, such as an epoxy resin or ethylene-based polymer which, when compounded with appropriate ingredients (typically a blowing and curing agent), expands and cures in a reliable and predicable manner upon the application of heat or the occurrence of a particular ambient condition. From a chemical standpoint for a thermally-activated material or a thermoset material, the structural foam is usually initially processed as a flowable thermoplastic material before curing. Such a material will typically cross-link upon curing, which makes the material incapable of further flow.

An example of a preferred structural foam formulation is an epoxy-based material that is commercially available from L&L Products of Romeo, Mich., under the designations L5206, L5207, L5208, L5209. One advantage of the preferred structural foam materials over prior art materials is that the preferred materials can be processed in several ways. The preferred materials can be processed by injection molding, extrusion compression molding or with a mini-applicator. This enables the formation and creation of part designs that exceed the capability of most prior art materials. In one preferred embodiment, the structural foam (in its uncured state) generally is dry or relatively free of tack to the touch and can easily be attached to the carrier member through fastening means which are well known in the art.

While the preferred materials for fabricating the expandable material have been disclosed, the expandable material can be formed of other materials provided that the material selected is heat-activated or otherwise activated by an ambient condition (e.g. moisture, pressure, time or the like) and cures in a predictable and reliable manner under appropriate conditions for the selected application. One such material is the epoxy based resin disclosed in U.S. Pat. No. 6,131,897, the teachings of which are incorporated herein by reference, filed with the U.S. Patent and Trademark Office on Mar. 8, 1999 by the assignee of this application. See also, U.S. Pat. Nos. 5,766,719; 5,755,486; 5,575,526; and 5,932,680, (incorporated by reference). In general, the desired characteristics of the expandable material include relatively high stiffness, high strength, high glass transition temperature (typically greater than 70 degrees Celsius), and adhesion durability properties. In this manner, the material does not generally interfere with the materials systems employed by automobile manufacturers. Exemplary materials include materials sold under product designation L5207 and L5208, which are commercially available from L & L Products, Romeo, Mich.

It is also contemplated that, when the member of the present invention is used for sealing or baffling, the expandable material may be designed to absorb or attenuate sound, block off and prevent passage of materials through a cavity or the like. As such, the expandable material may be configured to expand to greater than a volume that is at least 200%, at least 400%, at least 800%, at least 1600% or even at least 3000% or its original unexpanded volume. Examples of such expandable material are discussed in U.S. Application attorney docket no. 1001-141, filed Jun. 15, 2004, expressly incorporated by reference.

In applications where the expandable material is a heat activated, thermally expanding material, an important consideration involved with the selection and formulation of the material comprising the structural foam is the temperature at which a material reaction or expansion, and possibly curing, will take place. For instance, in most applications, it is undesirable for the material to be reactive at room temperature or otherwise at the ambient temperature in a production line environment. More typically, the structural foam becomes reactive at higher processing temperatures, such as those encountered in an automobile assembly plant, when the foam is processed along with the automobile components at elevated temperatures or at higher applied energy levels, e.g., during paint curing steps. While temperatures encountered in an automobile assembly operation may be in the range of about 148.89° C. to 204.44° C. (about 300° F. to 400° F.), body and paint shop applications are commonly about 93.33° C. (about 200° F.) up to about 193° C. (about 380° F.) or higher. If needed, blowing agent activators can be incorporated into the composition to cause expansion at different temperatures outside the above ranges.

Generally, suitable expandable foams have a range of expansion ranging from approximately 0 to over 1000 percent. The level of expansion of the expandable material 30 may be increased to as high as 1500 percent or more. Typically, strength and stiffness are obtained from products that possess lower expansion.

Some other possible materials for the expandable material include, but are not limited to, polyolefin materials, copolymers and terpolymers with at least one monomer type an alpha-olefin, phenol/formaldehyde materials, phenoxy materials, and polyurethane. See also, U.S. Pat. Nos. 5,266,133; 5,766,719; 5,755,486; 5,575,526; 5,932,680; and WO 00/27920 (PCT/US 99/24795) (all of which are expressly incorporated by reference). In general, the desired characteristics of the resulting material include relatively low glass transition point, and good adhesion durability properties. In this manner, the material does not generally interfere with the materials systems employed by automobile manufacturers. Moreover, it will withstand the processing conditions typically encountered in the manufacture of a vehicle, such as the e-coat priming, cleaning and degreasing and other coating processes, as well as the painting operations encountered in final vehicle assembly.

In another embodiment, the expandable material is provided in an encapsulated or partially encapsulated form, which may comprise a pellet, which includes an expandable foamable material, encapsulated or partially encapsulated in an adhesive shell. An example of one such system is disclosed in commonly owned, co-pending U.S. application Ser. No. 09/524,298 (“Expandable Pre-Formed Plug”), hereby incorporated by reference.

In addition, as discussed previously, preformed patterns may also be employed such as those made by extruding a sheet (having a flat or contoured surface) and then die cutting it according to a predetermined configuration in accordance with the chosen pillar structure, door beam, carrier member or the like, and applying it to thereto.

The skilled artisan will appreciate that the system may be employed in combination with or as a component of a conventional sound blocking baffle, or a vehicle structural reinforcement system, such as is disclosed in commonly owned co-pending U.S. application Ser. Nos. 09/524,961 or 09/502,686 (hereby incorporated by reference).

It is contemplated that the material of the expandable material could be delivered and placed into contact with the assembly members, through a variety of delivery systems which include, but are not limited to, a mechanical snap fit assembly, extrusion techniques commonly known in the art as well as a mini-applicator technique as in accordance with the teachings of commonly owned U.S. Pat. No. 5,358,397 (“Apparatus For Extruding Flowable Materials”), hereby expressly incorporated by reference. In this non-limiting embodiment, the material or medium is at least partially coated with an active polymer having damping characteristics or other heat activated polymer, (e.g., a formable hot melt adhesive based polymer or an expandable structural foam, examples of which include olefinic polymers, vinyl polymers, thermoplastic rubber-containing polymers, epoxies, urethanes or the like) wherein the foamable or expandable material can be snap-fit onto the chosen surface or substrate; placed into beads or pellets for placement along the chosen substrate or member by means of extrusion; placed along the substrate through the use of baffle technology; a die-cast application according to teachings that are well known in the art; pumpable application systems which could include the use of a baffle and bladder system; and sprayable applications.

Installing the Reinforcement, Sealing or Baffling Member To an Automotive Vehicle

Once completed, the reinforcement sealing or baffling member of the present invention is preferably installed to an automotive vehicle although it may be employed for other articles of manufacture such as boats, buildings, furniture, storage containers or the like. The member may be used to reinforce, seal or baffle a variety of components of an automotive vehicle including, without limitation, body components (e.g., panels), frame components (e.g., hydroformed tubes), pillar structures (e.g., A, B or C-pillars), bumpers, roofs or the like of the automotive vehicle.

In one preferred embodiment, the reinforcement, sealing or baffling member is placed at least partially within a cavity of a structure of an automotive vehicle wherein the cavity is defined by one or more walls or surfaces of the structure. Thereafter, the expandable material is activated to expand, wet, and adhere to one or more surfaces of the carrier member and one or more surfaces of the component of the automotive vehicle. Upon curing, the expandable material preferably forms a rigid structural or sealing or baffling foam securing the reinforcement member within the cavity of the structure of the vehicle thereby reinforcing the structure.

According to one exemplary embodiment shown in FIG. 3, there is illustrated the exemplary reinforcement member 10 that includes the carrier member 12 with the expandable material 14 disposed thereon. As shown, the reinforcement member 10 is suitable for placement adjacent to a structure 40 (e.g., a pillar structure) or within a cavity 42 of the structure 40, which is preferably a structure of an automotive vehicle. In the embodiment shown, the structure 40 has a cavity 42 corresponding to the configuration, particularly the outer surface 20, of the carrier member 12, the reinforcement member 10 or both. However, it shall be understood that the structure 40 may be formed in nearly any shape or configuration depending upon the intended use of the member 10 and depending upon other factors.

The carrier member 12, the reinforcement member 10 or both extend along an axis extending the length of the carrier member 12. The expandable material 14 in the particular embodiment illustrated is divided into multiple (e.g., four) masses 48 each disposed within one of the multiple cavities 28 of the carrier member 12 and extending lengthwise thereon.

The reinforcement member 10 may be inserted within the cavity 42 of the structure 40 in separate parts or as a unit. Upon insertion, the outer surface 20 of the carrier member 12, of the reinforcement member 10 or both are preferably adjacent and substantially opposing walls 50 defining the cavity 42, although not required. It should be understood that various supports or fasteners such as mechanical fasteners, adhesives, magnets, combinations thereof or the like, which may be integral with or attached to the reinforcement member and may be utilized to assist in locating the reinforcement member within the cavity at least until the expandable material is expanded and cured.

After insertion, the masses 48 of expandable material 14 are preferably activated as described herein to expand, contact and wet the walls 50 of the structure 40 and cure to adhere the reinforcement member 10, the carrier member 12 or both to the walls 50 of the structure 40 thereby forming a reinforced structural system. Advantageously, the reinforcement member 10 in this manner provides structural integrity to the structure 40 of the automotive vehicle.

In certain embodiments, it is contemplated that, prior to activation, measures may be taken to provide clearance between the reinforcement member and the walls of the structure into which the reinforcement member is placed. For example, the reinforcement member may be provided with spacers (e.g., small extensions), which are designed to maintain space between the walls and the reinforcement member prior to activation. Alternatively, portions of the expandable material may be placed or shaped such that those portions act as spacers. In this manner, e-coat can more easily coat the walls defining the cavity prior to activation of the expandable material.

It is also generally contemplated that the expandable material may be located upon the carrier member such that the carrier member and the walls of the cavity do not significantly contact each other. For example, the carrier may be substantially or fully encapsulated in the expandable material such that, upon activation, the expanded expandable material (i.e., the structural foam) provides a barrier between the carrier and the wall. Alternatively, the expandable material may be located such that, upon expansion, the expandable material spaces the carrier member away from the walls such that there is minimal contact therebetween. In this manner, any potential undesirable reactions (e.g., galvanic reactions or corrosive reactions), which might otherwise take place between the walls and the carrier, particularly when the walls and carrier are of dissimilar metals (e.g., where the structure is steel or ferrous and the carrier includes aluminum), can be avoided.

While the exemplary drawings of the invention feature a reinforcement member, it is contemplated that the skilled artisan will be able to form sealing or baffling members by shaping or configuring carrier members and expandable materials in known shapes and configurations, but using forming techniques described herein. Exemplary sealing and baffling members are disclosed in copending application Ser. No. 10/847,016, filed May 17, 2004; Ser. No. 10/941,553, filed Sep. 15, 2004; Ser. No. 10/686,845, filed Oct. 16, 2003 and Ser. No. 10/617,058, filed Jul. 10, 2003, all of which are incorporated herein by reference for all purposes.

Unless stated otherwise, dimensions and geometries of the various structures depicted herein are not intended to be restrictive of the invention, and other dimensions or geometries are possible. Plural structural components can be provided by a single integrated structure. Alternatively, a single integrated structure might be divided into separate plural components. In addition, while a feature of the present invention may have been described in the context of only one of the illustrated embodiments, such feature may be combined with one or more other features of other embodiments, for any given application. It will also be appreciated from the above that the fabrication of the unique structures herein and the operation thereof also constitute methods in accordance with the present invention.

The preferred embodiment of the present invention has been disclosed. A person of ordinary skill in the art would realize however, that certain modifications would come within the teachings of this invention. Therefore, the following claims should be studied to determine the true scope and content of the invention.

Claims

1. A process for reinforcing, sealing or baffling a structure of an article of manufacture, the process comprising:

forming a metal material into a carrier, the metal material including aluminum, magnesium or a combination thereof;

applying an expandable material to the carrier to form a member;

inserting the member within a cavity of the structure; and

activating the expandable material to expand, contact and wet internal walls of the cavity of the structure of the article of manufacture and to adhere the member within cavity.

2. A process as in claim 1 wherein the forming of the metal material includes shaping of a slurry of spherical or otherwise shaped solid particles in a liquid metal matrix.

3. A process as in claim 1 wherein the forming of the metal material includes a thixomolding process.

4. A process as in claim 1 wherein the structure is part of an automotive vehicle.

5. A process as in claim 1 wherein the metal material of the carrier is at least 85% metal.

6. A process as in claim 1 wherein the carrier member has an outer surface that is roughened or textured for allowing the expandable material to adhere to a surface of the carrier with greater strength.

7. A process as in claim 1 wherein the shape of the carrier corresponds to the shape of the cavity of the structure.

8. A process as in claim 1 wherein the expandable material is activated at a temperature experienced in an e-coat or paint oven.

9. A process for reinforcing a structure of an automotive vehicle, the process comprising:

forming a metal material into a carrier, the metal material including aluminum, magnesium or a combination thereof, the forming of the carrier including: i. forming metal masses into a slurry of solid particles in a liquid metal matrix; ii. feeding the slurry within a cavity of a mold; iii. solidifying the slurry within the mold to form the carrier into a desired shape

applying an expandable material to the carrier to form a reinforcement member;

inserting the member within a cavity of the structure; and

activating the expandable material to expand, contact and wet internal walls of the cavity of the structure of the article of manufacture and to adhere the member within cavity.

10. A process as in claim 9 wherein the solid particles or internally hollow for forming a cellular carrier member.

11. A process as in claim 9 wherein the mold is at a temperature of about 150° C. to abut 400° C.

12. A process as in claim 9 wherein the mold is at a temperature of about 200°0 C. to abut 250° C.

13. A process as in claim 9 wherein the forming of the metal masses into a slurry involve feeding the metal masses to a machine having a molding barrel and screw for at least partially melting the metal masses.

14. A process as in claim 9 wherein the forming of the metal material includes shaping of a slurry of spherical or otherwise shaped solid particles in a liquid metal matrix.

15. A process as in claim 9 wherein the forming of the metal material includes a thixomolding process.

16. A process as in claim 9 wherein the structure is part of an automotive vehicle.

17. A process as in claim 9 wherein the metal material of the carrier is at least 85% metal.

18. A process as in claim 9 wherein the carrier member has an outer surface that is roughened or textured for allowing the expandable material to adhere to a surface of the carrier with greater strength.

19. A process as in claim 9 wherein the shape of the carrier corresponds to the shape of the cavity of the structure.

20. A process as in claim 9 wherein the expandable material is activated at a temperature experienced in an e-coat or paint oven.