Abstract: A structural reinforcement for insertion into a cavity of a vehicle structure including a base reinforcing portion, an expandable material and a localized reinforcement is disclosed. The localized reinforcement is placed within the structural reinforcement at a location of anticipated increased deformation during vehicle impact in an effort to reduce deformation and control the load distribution post-impact.

Abstract: A vehicle roof frame includes an adhering structure having an adhesive carrier and an expanding structural adhesive coupled to at least a portion of an outer surface of the adhesive carrier. The expanding structural adhesive includes an installation state and a structural state, and the structural state has a larger volume than the installation state. The vehicle roof frame also includes a plurality of vehicle frame members that cooperate to form a frame joint and a joint cavity defined within the frame joint. The adhering structure is disposed within the joint cavity and the adhesive carrier and the expanding structural adhesive in the structural state substantially occupies the joint cavity and fixably couples the plurality of framing members such that the frame joint is free of supplemental mechanical connections proximate the joint cavity.

Abstract: Disclosed are various embodiments of expandable barriers. Expandable barriers are typically barriers made from an expandable material and formed to fit within a cavity. After being placed inside a cavity, expandable barriers generally undergo an activation process, where the expandable barrier expands to fill the cavity and create a physical barrier. Using various extrusion processes to form an expandable barrier allows for a reduction in tooling costs, while also allowing more flexible barrier designs. Such designs can be specifically tailored for a particular cavity or cavities to ensure that the barrier fills the cavity after expansion.

Abstract: A baffle for sealing a vehicle structure, comprising a carrier with an interior body portion characterized by a plurality of spaced-apart members, providing voids, and an expandable material, that may also have openings, disposed on the carrier which, upon expansion, fills a vehicle cavity and covers the interior body portion and each of the voids.

Abstract: An exhauster baffle is provided that may be used to prohibit fluid flow through a cavity except when a pressure on one side of the exhauster baffle is greater than a pressure on another side of the exhauster baffle. The exhauster baffle includes a body portion defining an opening, a sealer disposed on the body portion, and a flap disposed over the opening for regulating fluid flow through the opening. In one embodiment, the flap exposes the opening of the body portion to allow fluid to flow through the cavity when the pressure on one side of the exhauster baffle greater than the pressure on another side of the baffle to equalize pressure.

Abstract: A sealing device, such as a sealing bulkhead for a motor vehicle, is provided that can be arranged or is arranged between an inner column part of a motor vehicle and an outer column part of the motor vehicle and includes, but is not limited to a holder fixed on the inner column part, a separating body fixed on the a holder and at least sectionally closes a gap formed between the inner column part and the outer column part, as well as a supporting unit fixed on the separating body and on the outer column part in order to fix the outer column part on the inner column part.

Abstract: A structural mounting insert for sealing between and/or adhering to surfaces of members is described. The insert includes a base member and activatable material about the base material.

Abstract: A structural reinforcement for insertion into a cavity of a vehicle structure and method for making the same, the reinforcement including adjacent reinforcing segments and rigid bridges located between adjacent reinforcement segments. The rigid bridges are located for simplified separation of the reinforcement segments post-vehicle crash.

Abstract: A cavity filler for use in a hollow pillar of a vehicle. The cavity filler includes a carrier having a generally planar upper surface, an expandable foam mounted to the carrier wherein the expandable foam is mounted to the carrier around a peripheral edge of the carrier. The invention further includes a flange connected to the expandable foam (also made of the expandable foam) wherein the flange extends away from and generally parallel with the planar upper surface of the carrier. The extension and flange of the expandable foam are operable to extend the expandable foam to ensure a full filling of the expandable foam after the heat treating process. The fully occupied hollow cavity of the pillar with the expandable foam blocks the transmission of noise from the engine, wind and/or road noise through the pillars to the interior vehicle cabin.

Abstract: A frame sealing unit for a vehicle, that is disposed between a front pillar and a side outer panel of a vehicle, may include a main body where a mounting space is formed at one end thereof, a first pad that is inserted into the mounting space, a bonding member that is bonded to one side lower surface of the main body and an insert portion is formed on the exterior circumference thereof, a second pad that is inserted into the insert portion corresponding to the shape of the bonding member, a sub-body that is mounted on the bonding member in a position corresponding to one side surface of the main body and is spaced apart from the main body to form an operating space, and an expandable pad that is inserted into the operating space and slid when heated to an initial temperature.

Abstract: An acoustic spray foam control system and method are provided for a sunroof drain tube area in a vehicle. The system and method include an acoustic spray foam control baffle that is mounted within the sunroof drain tube area of the vehicle and a sunroof drain tube that is installed in the sunroof drain tube area by passing through the acoustic spray foam control baffle. The system and method also include acoustic spray foam that is injected into the sunroof drain tube area with flow of the acoustic spray foam controlled by the acoustic spray foam control baffle.

Abstract: A method for locally reinforcing or baffling a structure having a hollow cavity is disclosed. The present invention provides an insert that includes a carrier, a thermally expandable material located on at least a portion of the carrier, and at least one integrally formed attachment that projects outwardly from the carrier. The inserts of the present invention are preferably placed within a hollow cavity in a transverse direction so that once the insert is sealed into place via the thermally expandable material, the hollow cavity is separated into two separate chambers.

Abstract: A vehicle body includes a hollow structural member having an inner surface. The hollow structural member includes a first metal or metal alloy. A structural reinforcement member is positioned in the hollow structural member and includes a stiffener including a second metal or metal alloy different from the first metal or metal alloy. A gap is provided between the stiffener and the inner surface of the structural member. An adhesive is secured to the stiffener. The adhesive is substantially dry to the touch prior to activation and is activatable to expand toward the inner surface to fill at least a portion of the gap. A frame is secured to the stiffener and is positioned between the stiffener and the inner surface of the structural member to maintain the gap prior to expansion of the adhesive. The frame is adapted to insulate the stiffener from the hollow structural member.

Abstract: A method for fastening an in particular tub-shaped floor panel to an in particular frame-like vehicle structure is provided. The method includes applying an adhesive to a contact surface of the floor panel and/or of the vehicle structure, and joining the floor panel and the vehicle structure. The method includes expanding and/or activating the adhesive by heating the joint vehicle structure-floor panel composite.

Abstract: A device for reinforcing, baffling or sealing a vehicle structure that includes hinge structures for allowing the member to be moveable within a cavity and free of any spring effect during movement.

Abstract: There is disclosed a process of forming reinforcements, baffles and seals having malleable carriers. The process typically includes application of an activatable material to a malleable carrier and contouring of the activatable material the malleable carrier or both.

Abstract: A structural reinforcement for insertion into a cavity of a vehicle structure including a base reinforcing portion, an expandable material and a localized reinforcement is disclosed. The localized reinforcement is placed within the structural reinforcement at a location of anticipated increased deformation during vehicle impact in an effort to reduce deformation and control the load distribution post-impact.

Abstract: The present invention is predicated upon the provision of systems and methods for reinforcement of a structural member. More particularly, the present invention is predicated upon unique carrier configurations and application of reinforcing material thereto. In one configuration, the application of reinforcing material is achieved without the use of fasteners, adhesives, or both, for placement, locating and restrictive movement of the reinforcing material onto the carrier.

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: There is disclosed a member for sealing, baffling and/or reinforcing components of an automotive vehicle. The assembly generally includes a carrier, an expandable material and at least one fastener.

Abstract: The present invention is predicated upon the provision of systems and methods for reinforcement of a structural member. More particularly, the present invention is predicated upon unique carrier configurations and application of reinforcing material thereto. In one configuration, the application of reinforcing material is achieved without the use of fasteners, adhesives, or both, for placement, locating and restrictive movement of the reinforcing material onto the carrier.

Abstract: A front side member assembly includes a front side member body having at least one coupling hole at one surface thereof with a closed section shape, a bulkhead including a coupling portion and expansion foam that may be coupled to the coupling portion, wherein the bulkhead may be inserted into the front side member body in order to position the coupling portion at a position corresponding to the coupling hole, and the expansion foam may be hardened to reinforce rigidity of the front side member body.

Abstract: High-strength porous carbon and a method of its manufacture are described for multifunctional applications, such as ballistic protection, structural components, ultracapacitor electrodes, gas storage, and radiation shielding. The carbon is produced from a polymer precursor via carbonization, and optionally by surface activation and post-treatment.

Abstract: An impact protection structure for a vehicle impacting a blunt-object barrier includes a support structure of the vehicle, an energy absorbing rail coupled to the support structure, and a localized energy dissipation structure. The energy absorbing rail extends an energy absorbing rail length and includes a plurality of lumens. The localized energy dissipation structure extends a localized energy dissipation structure length less than the energy absorbing rail length.

Abstract: An attachment arrangement for a vehicle comprises a bracket having a first end part and a second end part. The first end part of the bracket is attachable to an inside of a first vehicle body part. The first vehicle body part is attachable to a second vehicle body part. A structural foam is arranged on the second end part of the bracket. The structural foam has an expansion factor such that when the structural foam is heated, the structural foam is expandable from the second end part of the bracket and adherable to the second vehicle body part.

Abstract: A baffle for sealing a vehicle structure, comprising a carrier with an interior body portion characterized by a plurality of spaced-apart members, providing voids, and an expandable material, that may also have openings, disposed on the carrier which, upon expansion, fills a vehicle cavity and covers the interior body portion and each of the voids.

Abstract: In the case of an element for sealing or reinforcing a cavity of a structural element, in particular of a vehicle, the element comprises a base element a foamable part, and an opening for receiving a penetrating element. A wing is arranged on the base element, the opening is open at the side and an actuator which moves the wing when the penetrating element is introduced is arranged on the wing.

Abstract: A structural reinforcement comprising a hollow profile and a ribbed structure, the ribbed structure including a laminar structure of two facing sheets with a first layer of adhesive material that is foamable and located in between the two facing sheets, the ribbed structure having ribs with one or more ends and a second adhesive material that is provided over at least part of the ribs at the one or more ends to bond the ribs at the one or more ends to an interior surface of the hollow profile.

Abstract: A panel assembly for a vehicle and a method of supporting the panel assembly is disclosed. The panel assembly includes a first wall and a bracket adjacent to the first wall. The bracket has a first platform facing the first wall. The panel assembly further includes a first support member attached to the first platform and defining an initial state and a final state. The first support member and the first wall define a first gap therebetween when in the initial state. The first support member is expandable to contact the first wall to remove the first gap when in the final state for supporting the first wall to prevent deformation of the first wall.

Abstract: A reinforced structure is disclosed which includes a structural component as well as a reinforcing part that is arranged in a cavity of the structural component. The reinforcing part can include a support part and a connection, the support part being arranged in the cavity such that a distance between the support part and the structural component at a position of the structural component with a higher probability of deforming under a force load from outside on the structural component is shorter than at a position of the structural component with a lower probability of deforming under a force load from the outside.

Abstract: An insert for sealing and acoustic damping of a longitudinal cavity having an interior surface, comprising: a) one or more carrier plates made of a polymeric material (A) which does not deform when heated to a temperature not higher than 180° C. and which comprises a main polymer (A1) which gives mechanical strength to the carrier plate, and—at least one vibration-damping polymer (A2), and b) a thermally expandable material (B). The vibration-damping polymer (A2) is preferably selected from the group comprising: thermoplastic polyurethanes, styrene/butadiene block copolymers, hydrogenated styrene/butadiene block copolymers, styrene/isoprene block copolymers, hydrogenated styrene/isoprene block copolymers, styrene/isoprene/styrene tri-block copolymers, and hydrogenated styrene/isoprene/styrene tri-block copolymers.

Abstract: A bodywork for vehicles including panels made of a deformable material and filled with a pressured fluid. The panels are located on the external sections of the bodywork.

Abstract: The present invention is predicated upon the provision of systems and methods for reinforcement of a structural member. More particularly, the present invention is predicated upon unique carrier configurations and application of reinforcing material thereto. In one configuration, the application of reinforcing material is achieved without the use of fasteners, adhesives, or both, for placement, locating and restrictive movement of the reinforcing material onto the carrier.

Abstract: There are provided a vehicle interior finishing laminate sheet in which a polypropylene resin foam board of high foaming extent having interconnected cells is used as a core member, a vehicle interior trim material, a method for manufacturing the vehicle interior finishing laminate sheet, and an apparatus therefor. The present invention relates to a vehicle interior finishing laminate sheet 1 provided with a core member consisting of a polypropylene resin foam board 2. The polypropylene resin foam board 2 is extrusion molded into a plate shape, and has an interconnected cell ratio of 50% or higher and a foaming extent of 10- to 50-fold. A plurality of polypropylene resin foam boards 2, 2 are joined to each other by the hot plate welding method or the laser transmission welding method, whereby a large-size core member of vehicle interior finishing laminate sheet 1, which is used for a roof lining or the like, can be formed.

Abstract: An uncured acoustic absorbing member for cavity sealing comprises a thermally inert carrier (8, 28) and a thermally expandable material (6, 26) applied to the carrier (8, 28). The carrier (8, 28) contains openings (3) which become covered when the thermally expandable material (6, 26) is expanded to seal the cavity. The thermally expandable material (6, 26) may be in the form of substantially discontinuous segments (25) having an area in the range of 0.25 to 400 mm2. The substantially discontinuous segments (25) provide a highly uniform expansion of the material when it is thermally expanded. The acoustic absorbing members are particularly useful for sealing automotive cavities to provide acoustical abatement and to prevent the entry of fluids into the cavity.

Abstract: Exemplary baffles for inhibiting noise transmission through a pillar structure, and exemplary methods of making the same, are disclosed. An exemplary baffle may include a body configured to be secured in a cavity, the body defining a passage for selectively receiving a line extending through the body. The baffle may further include an expandable material extending substantially about a perimeter of the passage. The expandable material may be configured to expand to seal the cavity about the body. The body may include a flap configured to open to allow the line to extend through the passage. The body may further include a biasing element urging the flap toward a closed position, substantially obstructing the passageway.

Abstract: A structural mounting insert for sealing between and/or adhering to surfaces of members is described. The insert includes a base member and activatable material about the base material.

Abstract: A structural reinforcement for insertion into a cavity of a vehicle structure including a base reinforcing portion, an expandable material and a localized reinforcement is disclosed. The localized reinforcement is placed within the structural reinforcement at a location of anticipated increased deformation during vehicle impact in an effort to reduce deformation and control the load distribution post-impact.

Abstract: A body part of a front frame of a motor vehicle has a structural component of plastic arranged in a frame part. The structural component is connected with a cage nut through material connection. Via the cage nut a front axle is screwed to the body part. A carrying part for holding the cage nut is welded to the frame part for this purpose and connected to the structural component via over molding.

Abstract: An automotive energy dissipation device includes a bladder disposed adjacent to an interior surface of a body panel of an automobile. A protective liner is disposed between the bladder and the body panel. A valve for inflating the bladder is associated with the bladder. Additionally, a pressure relief valve is associated with the bladder. The automotive energy dissipation device functions when pressure within the bladder exceeding a preset limit attributable to compression during an impact is released through the pressure relief valve. As air exits the pressure relief valve it dissipates energy. This in turn reduces the damage and severity of a crash thereby better protecting the occupants from injury.

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, an expandable material, and an adhesive. The expandable material and the adhesive are placed within the carrier such that when the expandable material expands, the adhesive moves to be positioned to bond the rigid carrier to the cavity walls.

Abstract: An inflatable electric and hybrid vehicle system, that has the features and accoutrements of traditional automotive vehicles, that is extremely safe, lightweight, inexpensive, compact and energy efficient. The system designed to be shipped by common carrier and then assembled in a few hours with a minimal amount of tools or effort. The vehicle has either an inflatable body or membrane skin with a hybrid-type or electric motor drive train as well as heating and cooling system and inflatable seats. The battery power supply utilizes banks of commonly available batteries charged by a mobile onboard charger, configured to be easily removed with agnostic software and hardware to manage the power source They are also networked via wireless communication to various base stations to allow for monitoring and exchange of battery banks quickly and efficiently.

Abstract: A bodywork for vehicles including panels made of a deformable material and filled with a pressured fluid. The panels are located on the external sections of the bodywork.

Abstract: There is disclosed a noise reduction member. Preferably, the noise reduction member is employed for sealing or baffling within a pillar or other structure of an automotive vehicle, although not required.

Abstract: A reinforced structural assembly includes a first vehicle component and a second vehicle component attached to the first vehicle component to define a substantially closed cavity. An acoustic foam member is contained within a container, also referred to as a vehicle pouch, containing the acoustic foam member and is made of a material that has a predetermined strength. A sealant with adhesive properties is included on at least a portion of an outer surface of the container, and is impregnated within or coated onto the container. The container and the acoustic foam member substantially fill the cavity so that the outer surface of the container contacts at least a portion of an inner surface of the vehicle components and the sealer seals the acoustic foam member and adheres the container to the inner surface of the attached vehicle components. A method of reinforcing vehicle components is provided.

Abstract: A modifiable structural assembly comprising an active material based insert positioned within a hollow structural member, wherein the insert defines a first insert dimension, is configured, when activated, to change the first insert dimension to a second insert dimension, and selectively achieving the first or second dimension facilitates positioning the insert, or changes a characteristic of the assembly, such as the stiffness, damping effect, or energy absorption rate, once the insert has been positioned.

Abstract: A seat support assembly for supporting a vehicle seat on a floor panel member includes a cross member extending laterally across the floor panel member. Ends of the cross member are spaced laterally inward relative to side edges of the floor panel for providing ingress/egress areas between the ends and the side edges. A foam spacer member is complementarily received inside each of the ends of the cross member. Each of the foam spacer members is secured to the floor panel for transferring load forces from the cross member to the floor panel.

Abstract: A heat expandable baffle having a shape corresponding to, but smaller than, the shape of the cross section of a cavity to be sealed, and comprising a rigid support plate, a carrier for a heat expandable material and a heat expandable material mounted only to the outer periphery of the carrier. When activated by heating, the expandable material expand radially from the carrier to seal the cross sectional gap between the carrier and the cavity wall.

Abstract: The present invention is predicated upon the provision of systems and methods for reinforcement of a structural member. More particularly, the present invention is predicated upon unique carrier configurations and application of reinforcing material thereto. In one configuration, the application of reinforcing material is achieved without the use of fasteners, adhesives, or both, for placement, locating and restrictive movement of the reinforcing material onto the carrier.

Abstract: A bladder system and method for reinforcing at least a portion of a structural member, including a flexible barrier member for dividing at least a portion of the structural member being reinforced into one or more sections; and a reinforcement material for filling one or more sections bounded by the flexible barrier member. The reinforcement material filling one or more sections of the structural member can be a pumpable polymeric material, and the flexible barrier member can be a polymeric material.