Abstract: An upper pillar structure of a vehicle may include a pad assembly for sealing an air intake portion formed between a side inner panel and a side outer panel, the pas assembly including a fixing member disposed at lower side of the air intake portion, and a rotating member, a portion of which is rotatably coupled to the fixing member and moves to top portion of the air intake portion by actuation of the side outer panel.

Abstract: A light-weight vehicle component such as a vehicle chassis (100) formed from an internally reinforced rigid closed-cell foam (12). The reinforced closed-cell foam vehicle chassis (100) includes an outer layer of rigid closed-cell foam (108a), an inner layer of rigid closed-cell foam (108c), and one or more layers of reinforcing structural material (114) disposed between the inner and outer layers of foam. The reinforced closed-cell foam vehicle chassis incorporates reinforced attachment points (114a) for receiving and supporting vehicle components, such as suspension elements, steering components, a drive motor, and passenger accommodations.

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 heat expandable baffle for sealing automotive cavities comprising a carrier plate with an outer perimeter and a strand of a heat expandable material along the major part of the outer perimeter, this strand circumscribing a central section of the carrier plate which is not covered by the heat expandable material, the outer perimeter defining a mean plane limited by the outer perimeter, the central section of the carrier plate being bent away from the mean plane in a way that the point on the central section which has the greatest distance from the mean plane lies at a distance from the mean plane which is at least 5% of the maximum linear length of the carrier plate, and/or the central section having a lumped mass distribution.

Abstract: A molding system includes a clip and a molding. The clip attaches to at least one panel of a vehicle. The clip includes a body that presents a surface. A pair of lips extends from the body in opposition to the surface. A fastener extends from the surface and is configured for engaging the at least one panel of the vehicle. A sealant is disposed on the surface. The sealant is configured to expand upon application of a condition such that the sealant engages the at least one panel of the vehicle to retain the clip to the at least one panel of the vehicle. The molding is configured to snap over the pair of lips on the clip such that the molding is secured to the at least one panel of the vehicle.

Abstract: Some embodiments comprise an integrated reinforcing crossmember having a carrier with an expansible material adhered to at least a portion of the exterior surface of the carrier. The carrier is comprised of a center section and two end sections, each section comprised of external lateral walls and internal ribs joined by cross walls and horizontal connecting walls. The crossmember is inserted into a cavity of a corresponding structural member, and the expansible material is activated and expands, securing the crossmember in place within the cavity.

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 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: 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: Cushions for dynamic impact applications include anisotropic cellular polymers made in an extrusion, expanded bead or reactive foaming process. The anisotropic behavior represented by CE/CT, CV/CT and CH/CT, wherein CE, CV and CH represent the compressive strength of the cellular polymer in each of three orthogonal directions E, V and H, respectively, as measured by compressing a 25-50 mm thick sample of the cellular polymer at a strain rate of 0.08 s?1 to 25% strain, CT represents the sum of CE, CV and CH, and at least one of CE/CT, CV/CT and CH/CT has a value of at least 0.40, up to about 0.80. The cellular polymer also preferably has density of 1.75 to 2.35 pounds/cubic foot and a compressive stress in the direction of maximum compressive strength of 290-600 kPa at 25% strain when used for headliner countermeasure applications. The cushions are useful in automotive applications such as automotive headliners, door panels, knee bolsters, pillars, headrests, seat backs, load floors or instrument panels.

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: 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: 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 lengthwise extended component contains of a support that possesses flow channels in the direction of its longitudinal axis. The support additionally possesses external surfaces that are offset to each other in the direction of the longitudinal axis as well as a lateral external surface. These external surfaces are provided with a layer of a thermally expansible and curable composition. Reinforcing components of this type are suitable for stiffening and/or reinforcing hollow supports, such as the A-, B- or C-pillars, the roof edges or the rocker panels of vehicles, especially passenger cars.

Abstract: A method of operating a volume-filling structure, comprising sensing an impact event and expanding the volume-filling structure from a non-expanded state to an expanded state upon the sensed impact event. The volume-filling structure comprises an open celled material, a first end cap connected to one end of the open celled material and a second end cap connected to a second end of the open celled material. The volume-filling structure further includes an activation mechanism regulating expansion of the open celled material from the non-expanded state to expanded state in response to an activation signal, and the activation mechanism includes an actuator interfaced with the end caps. Embodiments may include triggering a pneumatic device to force the second end cap from the first end cap. Additionally, embodiments may include triggering a mechanical event to force the second end cap from the first end cap.

Abstract: An acoustic baffle assembly for sealing or baffling a hollow body having a mass of heat activated expandable material that is capable of activating at a predetermined temperature. A substrate supports the mass. The substrate has a central portion and spaced apart projections extending outwardly from the central portion. The projections are configured to control expansion of the mass.

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: An injection molded foam article including a structure and a projection projecting from the structure. The thickness of the projection is greater than 40% of the thickness of the structure and the front surface of the structure opposite the projection is free of sink marks.

Abstract: The present invention is an article comprising a shaped rigid foam part; a heat activated foamable adhesive applied directly to at least a portion of the outer surface of the shaped foam part and an integral locating means. A second aspect of the invention is a method of forming a foam filled vehicle hollow member comprising, (a) inserting into a vehicular hollow member a rigid foam part comprised of a rigid foam having a heat activated foamable adhesive on at least a portion of the rigid foam insert and at least one integral locating means extending from a surface of the rigid foam, (b) engaging the locating means with the hollow member to locate the rigid foam part within the hollow member, and (c) heating the hollow member having the rigid foam part therein to a temperature and for a time sufficient to activate the heat activated expandable adhesive to form the foam filled vehicle hollow member.

Abstract: A method for reinforcing, baffling and/or sealing components of an automotive vehicle is disclosed. The method includes providing a carrier and disposing masses of expandable material onto the carrier. The method further provides for providing a fastener connected to the carrier.

Abstract: A method is provided for filling a hollow structure with metal foam. A mixture is made of a metal powder and a foaming agent. An electric resistance heating wire is provided and the mixture is consolidated into a solid preformed charge with the wire embedded in the charge and extending from the ends thereof. The preformed charge is placed into the hollow structure and electric current is applied to the resistance heating wire so that the metal powder is melted and the foaming agent foams the melted metal to fill the hollow structure.

Abstract: Force and deceleration delimiting methods for operating the same in a vehicle generally include an open celled material expandable from a non-expanded to an expanded state, wherein the material is sandwiched between first and second end cap members; an optional support surface cooperatively positioned with the material to cover a surface of the material in the expanded and non-expanded states; an optional shield cooperatively positioned with the material to cover a surface of the material in the expanded and non-expanded states; and an activation mechanism adapted to regulate selective expansion of the material from the non-expanded to the expanded state in response to a triggering event, wherein the support surface and/or shield have a compact shape when the material is in the non-expanded state and an expanded state when the material is in the expanded state.

Abstract: There is described a manufacturing method of motor vehicles which achieves the object of reducing the costs deriving from the manufacturing of vehicles belonging to different segments and the costs deriving from the traditional assembly of vehicles which starts from the external shell onto which the elements forming the interiors and the mechanical members are assembled, by suggesting the arrangement of a single self-supporting structural element formed by composite material, already provided with many interior elements, to which a new other interior elements, bodywork elements and mechanical elements can be connected in any assembly order.

Abstract: A structural member reinforcement includes a body portion having a plurality of side walls. The side walls are spaced to define an opening therebetween. A plurality of cells are disposed in the opening between the side walls. Each of the plurality of cells defines a channel. An expandable material, such as structural foam or noise vibration and harshness (NVH) foam, is disposed in the channel of at least one of the plurality of cells. The reinforcement may be used to reinforce a structural member, such as a vehicle frame. The structural member may define a cavity, and the reinforcement may be disposed within the cavity.

Abstract: A reinforcement member and reinforcement system for an article of manufacture (e.g., an automotive vehicle) are disclosed. The reinforcement member includes a carrier member and a reinforcement material and the carrier member includes one or multiple portions. The one portion or at least one of the multiples portions includes a reinforced portion that is divided into multiple sections.

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 system for absorbing impact energy includes a container formed with a plurality of faces. An energy absorbing material is substantially contained within the container. A first elongated member has a proximate end and a distal end. The proximate end is proximate and approximately perpendicular to a first face of the container. A long axis of the first elongated member intersects the first face. A first bumper is connected to the distal end of the first elongated member. A second elongated member has a proximate end and a distal end. The proximate end is proximate and approximately perpendicular to a second face of the container. A long axis of the second elongated member intersects the second face. The second elongated member is approximately perpendicular to the first elongated member. A second bumper connected to the distal end of the second elongated member.

Abstract: A system for absorbing impact energy includes a container formed with a plurality of faces. An energy absorbing material is substantially contained within the container. A first elongated member has a proximate end and a distal end. The proximate end is proximate and approximately perpendicular to a first face of the container. A long axis of the first elongated member intersects the first face. A first bumper is connected to the distal end of the first elongated member. A second elongated member has a proximate end and a distal end. The proximate end is proximate and approximately perpendicular to a second face of the container. A long axis of the second elongated member intersects the second face. The second elongated member is approximately perpendicular to the first elongated member. A second bumper connected to the distal end of the second elongated member.

Abstract: There is disclosed a reinforcement member with a carrier member and a reinforcement material disposed on the carrier member.

Abstract: An improved structural reinforcer is provided, some embodiments comprising expansible material disposed on a carrier, the carrier having a plurality of chambers arranged longitudinally, with locking slots and shutoffs that lock a portion of the expansible material to the carrier, and a channel that permits the flow of liquids within a structural member in which the structural reinforcer is disposed.

Abstract: Reinforcement components for structural members are disclosed. The reinforcement components have expansible reinforcement material that adheres to and reinforces structural members following activation. Methods of reinforcing are disclosed. Reinforced structural members are described.

Abstract: A volume-filling mechanical structure comprising a honeycomb celled material expandable from a compact state to an expanded state and methods for operating the same.

Abstract: An overlay component (such as a seal) is provided for mounting to an elongated vehicle structure (such as a door check link) without passing the overlay over the end of the structure. The overlay component has a first body section and a second body section comprised of resilient material. The first body section has a first structure receiving portion and a first interlocking portion. The second body section has a second interlocking portion complementary with the first interlocking portion. The first and second interlocking portions resiliently deform as they are interlocked while the elongated vehicle structure is being received by the first structure receiving portion, thereby retaining the overlay component on the elongated vehicle structure without adhesives or fasteners.

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 resin garnish installation structure installed to a vehicle body exterior surface, having a resin garnish which extends along a longitudinal direction thereof, the resin garnish including: an exterior surface which is level with the vehicle body exterior surface; a first edge which extends along the longitudinal direction; a second edge which is provided on an opposite side of the first edge and extends along the longitudinal direction; and an end part provided at a tip in the longitudinal direction, wherein in a vicinity of the end part, the second edge gradually curbs toward the first edge, and the second edge joins the first edge at the end part, and the resin garnish is installed so that a gap is formed between the end part and the vehicle body exterior surface, the gap becoming wider as it gets closer to the tip of the resin garnish.

Abstract: The present invention relates to a morphing cellular structure. The morphing cellular structure comprises a group of unit cells with each unit cell configured to have a cellular geometry. The group unit cells are formed of an active material, where the active material has both a first state and a second state. The active material is responsive to an actuation signal such that when the actuation signal is actuated, the active material is deformed from the first state to the second state, thereby changing the volume of each unit cell affected by the actuation of the actuation signal and morphing the cellular structure. Furthermore, both a passive material and at least one additional active material can be attached with the active material, allowing a user to selectively change the shape of the cellular structure.

Abstract: A structural member reinforcement includes a body portion having a plurality of side walls. The side walls are spaced to define an opening therebetween. A plurality of cells are disposed in the opening between the side walls. Each of the plurality of cells defines a channel. An expandable material, such as structural foam or noise vibration and harshness (NVH) foam, is disposed in the channel of at least one of the plurality of cells. The reinforcement may be used to reinforce a structural member, such as a vehicle frame. The structural member may define a cavity, and the reinforcement may be disposed within the cavity.

Abstract: In an attachment structure of an EA component, the EA component composed of a synthetic resin such as rigid urethane foam is attached to a trim serving as a member, with a first locking part therebetween. The first locking part includes a cylindrical part, an anchor, a flange, and a plurality of projections. The anchor has a flange shape extending from the rear end of the cylindrical part toward the outside. The flange extends from the leading end of the cylindrical part toward the outside. The projections protrude from the leading end of the cylindrical part in the direction parallel to the axis of the cylindrical part. The EA component is attached to the trim by setting the EA component on the trim while the projections are inserted in an opening.

Abstract: A structural reinforcement device for insertion into a cavity of a structure and method for making the same including a first reinforcement section that has at least one projection of a first expandable polymeric material secured to it; and a separate second reinforcement section mated with the first reinforcement section, the second reinforcement section being configured to include at least one cavity, into which the at least one projection penetrates upon mating, and at least one aperture defined therein through which the expandable material flows during expansion and where it will remain upon curing of the material, thereby causing the first reinforcement section to be coupled with the second reinforcement section.

Abstract: A vehicle body frame structure having two closed cross sections is disclosed. Each of the closed cross sections is isolated in a longitudinal direction of the vehicle body frame by barriers and structural foam fillers. The barriers are spot welded to the front and back of a reinforcement panel of the vehicle body frame.

Abstract: A mechanism suitable for assisting in the securing of expansible material to a carrier is disclosed.

Abstract: Reinforcement components for structural members are disclosed. The reinforcement components have expansible reinforcement material that adheres to and reinforces structural members following activation. Methods of reinforcing are disclosed. Reinforced structural members are described.

Abstract: A skeleton structure member made up of a skeleton member (11) having a cross-sectionally closed space (16, 33, 43, 63, 73, 83, 93) and multiple granules (17) packed inside the skeleton member. A granule flow allowing part (14, 42, 61, 71, 81, 92) for allowing movement of the multiple granules is provided inside the skeleton member and suppresses excessive rising of internal pressure within the skeleton member. The granule flow allowing part is provided in the vicinity of the multiple granules.

Abstract: There is disclosed a reinforcement member with a carrier member and a reinforcement material disposed on the carrier member.

Abstract: There is described a member for baffling, reinforcement or sealing. Typically, the member includes an internal portion and external portion wherein at least one, but typically both the internal and external portions include an activatable (e.g., expandable) material.

Abstract: Parts are provided which combine structural reinforcement of hollow profiles and light weight means of attachment. Optionally, the part may also provide an acoustic baffle. The parts consists of a core coated with expandable structural reinforcing foam on at least part of its surface the core being provided with means for receipt of a nut and means to prevent rotation of the nut. Optionally, a piece of a second expandable material is provided on at least one extremity which can expand to fill the entire cross section of the hollow profile. In a preferred embodiment, the hollow profile is the A, B or C pillar of a vehicle and the nut is used for attaching doors.

Abstract: An expandable insert and a method of making the same are disclosed. An expandable insert may generally include an expandable body that extends along a hollow structure, and has a continuous outer periphery. A passageway extends through the outer periphery that allows fluid communication therethrough. The expandable insert is operable to be expanded to fill a cross-section of the hollow structure. A method of forming an expandable insert may generally include forming an expandable body, including forming a continuous outer periphery and a passageway extending through the outer periphery to allow fluid communication therethrough. The method may further include expanding the elongated body to fill a cross-section of the hollow structure.

Abstract: The present invention relates to one-piece reinforcement elements consisting of an elongate shell-shaped basic body, the inner space of which has reinforcement ribs which are fixedly connected to the basic body, the reinforcement ribs consisting of plastic injection-molded on and their connection to the basic body taking place at discrete connection points via perforations in the basic body through which the plastic passes and extends over the surfaces of the perforations, and of a rigid structure reinforcement which is appended from the same plastic, by means of the same injection-molded operation, at at least one end of the basic body and which corresponds essentially to the form of the cross section of the hollow profile to be reinforced at this point of a body, an expandable adhesive material being applied over a portion of the surface of the rigid structure reinforcement and of the elongate shell-shaped basic body, the form of the rigid structure reinforcement and of the elongate basic body and also the

Abstract: A configuration for sealing or sound-proofing cavities, for example in the vicinity of a chassis or a body of a motor vehicle, includes two half-shells which are separately produced, which can be locked together and which, in an interlocked state, form a free, outwardly open ring-shaped gap in an outer, intermediate peripheral edge region. The ring-shaped gap is inwardly limited by an inner contour on one of the half-shells. A heat-expansible element as a contoured ring-like plate has a form which substantially corresponds to that of the ring-shaped gap formed between the two half-shells on their outer wall. The configuration is material-saving and can be produced and mounted at low cost.

Abstract: A two layer sound deadening material is formed from pumpable material applied through a pair of extrusion heads mounted on a single mount. A robot, used in high speed mass production automotive assembly lines, moves the door panel relative to the stationary extrusion heads to allow the simultaneous application of the two layers onto the interior side of the door. The first layer is formed of a thermosetting composition containing epoxy, rubber and a catalyst and adheres directly to the door panel. The second layer is formed of a thermosetting composition containing an epoxy resin, a thermo plastic copolymer and a curative which will adhere directly to the first layer due to similar chemical structures. The second layer is positioned such that the edges thereof are inside of the corresponding edges of the first layer to prevent read through transmission of noise from the body or door panel.