Abstract: So that intake water cannot flow from a frame side member of the body structure by way of a seat cross member into an exterior side member of the vehicle, a so-called partition part is arranged between the frame side member and the seat cross member, which partition part comprises a basic part and an expansion foam arranged thereon. As a result of the effect of heat, the expansion foam can expand to such an extent that the passage surface in the seat cross member is closed off in a watertight fashion and water can no longer enter the cross member.

Abstract: An automotive vehicle having a passenger cabin includes a floorpan with seats mounted to the floorpan. Side closure structures adjoin the outboard ends of the seats. Seat displacement members located within the side closure structures load the outboard ends of the seats so as to deform the seat frames and floorpan. This moves the affected seat laterally inward with respect to a longitudinal center plane of the vehicle in the event of a laterally directed impact load against the closure structure. As a result, the pelvic region of the occupant will be the first region of the occupant to be dynamically loaded by the side closure structure.

Abstract: A method of manufacturing a vehicle body part embeds an insert piece into a foamed layer of the body part by holding the insert piece in a foaming tool using a magnetic force. The magnetic force holds the insert piece into position, eliminating the need for any additional holding structures in the foaming tool. A body part made by this method has improved visual quality, particularly at a transition area between the insert piece and a decorative part.

Abstract: A structural reinforcement for a hollow section at least part of at least one of whose surfaces is the internal surface of an external panel comprising a rigid reinforcing member having a shape that substantially conforms to the cross section to be reinforced. An expandable adhesive material is provided over a portion of the surface of the rigid reinforcing member and the shape of the rigid reinforcing member and the amount and location of the expandable adhesive is such that upon foaming the foam contacts and bonds to the internal surfaces of the hollow section other than the interior surface of the external panel. In this way deformation of the external body panel during the foaming and/or cooling of the foamed expandable material is reduced or prevented.

Abstract: A sound insulation device for mounting in a tubular part, in particular a motor vehicle bodywork part, the device comprising a partitioning insert, a cord of a composition that is thermally expandable so as to form a foam, said cord being fitted to the periphery of the insert, retaining means for holding the cord on the insert prior to expansion of the cord, and means for encouraging the cord to expand towards the inside wall of the tubular part, wherein the cord is formed by being extruded in rectilinear manner without any particular shaping, and wherein the cord retaining means are integrally molded with the partitioning insert and also serve to shape the extruded cord around the periphery of the partitioning insert.

Abstract: An automotive vehicle sound absorption system. An expandable material, such as an polymer-based foam, is disposed on a surface of a wall. Upon activation, the foam transforms, preferably during an automobile assembly operation, and remains bonded to surface for sound absorption.

Abstract: A structural reinforcement member include a carrier member and a reinforcement material disposed upon the carrier member. The reinforcement member also includes at least one locating member. The reinforcement member has been found particularly useful for forming a structural system for articles of manufacture such as automotive vehicles.

Abstract: A door intrusion beam is of laminated construction and has a base metal stamping with end flanges, with metal stamping being of an inverted generally U-shaped cross section. Slidable and nested on the base metal stamping are a plurality of slidable and stackable elongated plastic elements each having a generally M-shaped configuration. The first plastic element next to the metal stamping and all stackable elongated plastic elements are secured together by layers of adhesives where surfaces contact one another. The plastic elements are of varying length.

Abstract: The present invention describes a hollow structural body such as an automotive unibody or frame rail that is reinforced with a reinforcing material such as a polyurethane foam by inserting into a portion of the structural body a bulkhead-containing insert, which, in combination with the structural body at the place of insertion, creates a containment region for the reinforcing material. Uncured reinforcing material can then be added to the containment region and cured.

Abstract: An automotive vehicle frame reinforcement system has a skeleton member designed to be secured to a vehicle frame, such as a roof or pillar section. An expandable material, such as an epoxy-based reinforcing foam, is disposed on the skeleton member. Once the system is attached to the frame, the foam expands and cures during an automobile assembly operation, bonding the reinforcement system to the frame. As a result, the reinforcement system provides enhanced load distribution over the vehicle frame without adding excessive weight.

Abstract: A modular segmented structural reinforcement system for use with closed forms or cavities defined with automotive vehicles having a plurality of modular segments designed to be secured within a defined portion of an automotive vehicle applications. An expandable or bonding material, such as an epoxy-based reinforcing foam or other sound absorption, damping, vibration reduction, or sealing material is disposed on at least a portion of the outer surface of each of the plurality of segments. Once the system is flexible fitted within the closed form or placed within a selected cavity of an automotive vehicle, the material expands and cures during an automobile assembly operation, bonding the reinforcement system to the segments. As a result, the reinforcement system provides enhanced load distribution over the vehicle frame without adding excessive weight and further serves to reduce noise and vibrational characteristics of the automotive vehicle.

Abstract: A modular segmented structural reinforcement system for use with closed forms or cavities defined with automotive vehicles having a plurality of modular segments designed to be secured within a defined portion of an automotive vehicle applications. An expandable or bonding material, such as an epoxy-based reinforcing foam or other sound absorption, damping, vibration reduction, or sealing material is disposed on at least a portion of the outer surface of each of the plurality of segments. Once the system is flexible fitted within the closed form or placed within a selected cavity of an automotive vehicle, the material expands and cures during an automobile assembly operation, bonding the reinforcement system to the segments. As a result, the reinforcement system provides enhanced load distribution over the vehicle frame without adding excessive weight and further serves to reduce noise and vibrational characteristics of the automotive vehicle.

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: A side structure (21) included in a railroad car is provided with an window opening (22), and door openings (23, 24) formed on the longitudinally opposite sides of the window opening (22), respectively. The side structure (21) excluding parts corresponding to the window opening (22) and the door openings (23, 24) are divided into a plurality of sections. A first section (S1)1 extends vertically between the window opening (22) and the door opening (23), a second section (S12) extends vertically between the window opening (22) and the door opening (24), and a third section (S13) of a width substantially equal to that of the window opening (22) extends under the window opening (22). Each of the sections has a core (2) attached to the inner surface of an outer panel (1), and rim members (3) having a substantially Z-shaped cross section and surrounding the core (2). An inner panel (4) is attached to the core (2) and the rim members (3) so as to cover the inner surface of the core (2).

Abstract: So that intake water cannot flow from a frame side member of the body structure by way of a seat cross member into an exterior side member of the vehicle, a so-called partition part is arranged between the frame side member and the seat cross member, which partition part comprises a basic part and an expansion foam arranged thereon. As a result of the effect of heat, the expansion foam can expand to such an extent that the passage surface in the seat cross member is closed off in a watertight fashion and water can no longer enter the cross member.

Abstract: An automotive vehicle frame reinforcement system has a skeleton member designed to be secured to a vehicle frame, such as a roof or pillar section. An expandable material, such as an epoxy-based reinforcing foam, is disposed on the skeleton member. Once the system is attached to the frame, the foam expands and cures during an automobile assembly operation, bonding the reinforcement system to the frame. As a result, the reinforcement system provides enhanced load distribution over the vehicle frame without adding excessive weight.

Abstract: A closed channel structural member, such as a side rail or a cross member, for use in such a vehicle body and frame assembly that includes an internal reinforcing structure to increase the strength and rigidity thereof. The side rail can be generally rectangular in cross sectional shape, including first and second side rail sections having generally C-shaped cross sectional shapes. The reinforcing structure can be generally hat-shaped or W-shaped in cross sectional shape, including a central reinforcing portion extending between a pair of base portions. The central reinforcing portion can either be laterally spaced apart from or directly abut a central web portion of one of the side rail sections. The base portions can be generally L-shaped in cross sectional shape, including legs that terminate adjacent to the ends of the other of the side rail sections to facilitate the assembly process. A pair of such reinforcing structures can be disposed within the side rail and abut one another in end-to-end fashion.

Abstract: A reinforced structural assembly and a method of using the assembly for reinforcing components of an automotive vehicle. The assembly generally includes a first member and a second member with a reinforcement material intermediate the first and second member. According to the method, the assembly is placed in a cavity of an automotive vehicle and the reinforcement material is expanded to promote connection between the first member and a surface defining the cavity and to promote connection between the second member and another surface defining the cavity.

Abstract: An assembly having one or more members (e.g., panels), a first expandable material and a second expandable material is disclosed. One of the materials is typically more expandable than the other. Although, the assembly may be used for various articles, it has been found particularly suitable for roofs of automotive vehicles.

Abstract: The invention seeks to solve the problem of providing sound insulation in tubular parts regardless of the section shape of the part that is to be insulated, and without using an insert that is of high cost. To this end, the invention proposes using a piece of material that is suitable for expanding over the entire section of the section, which piece is mounted using a support suitable for fixing to the wall of the tube that is to be insulated. In a particular embodiment, a sound insulation assembly mounted in a part presenting a longitudinal direction and a tubular wall comprises a wafer that is thermally expandable to form a foam, said wafer having two parallel main faces and extending essentially along a main plane from a first wall portion towards the diametrically opposite wall portion, together with a wafer support comprising a clamp for retaining the wafer prior to expansion and coupled to fixing means in the form of a clip for fixing to the first wall portion of the part.

Abstract: There is disclosed a reinforcement member with a carrier member and a reinforcement material disposed on the carrier member. The carrier member includes one or more first body members disposed at angles relative to one or more second body members. The carrier member also preferably includes connector members interconnecting the body members. The body members of the carrier are preferably arranged in a zig-zag configuration, which can collapse in an accordion-like manner.

Abstract: A mechanical, active crash pulse management structure for providing modification of crash pulse, wherein the structure has a dormant (initial) state volume, but then in the event of a crash, timely expands into a much larger deployed volume for providing management of an expectant crash energy. The preferred crash energy management structure is a before expansion honeycomb celled material brick, wherein expansion of the honeycomb brick is in a plane transverse to the cellular axis of the cells thereof, and crash crush is intended to be parallel to the cellular axis. In the event of a crash, either an active or passive activation mechanism is provided for causing expansion of honeycomb celled material.

Abstract: A reinforced sleeve including a carrier member and a reinforcing medium supported by the carrier member. The carrier is an elongated polymer member, and the reinforcing medium extends along at least a portion of the length of the carrier member. The reinforcing medium is preferably an epoxy-based resin. More particularly, the reinforcing medium is preferably a heat-activated structural foam.

Abstract: A seal attachment fixture and method are provided for attaching a seal to an encapsulated gasket disposed on a work piece, for example, an automotive window assembly. The seal attachment fixture includes fixture members, which slidably move into contact with openable lip portions on the gasket, thus exposing a retention slot defined therein. With the gasket retention slot open, a seal is then inserted within the slot.

Abstract: A bumper system includes a bumper beam having a face and ends, and an energy absorber mounted on the face. The energy absorber has a one-piece injection-molded non-foam piece with box sections and interconnecting straps, and a one-piece or multi-piece foam component securely insert-molded onto the injection-molded non-foam piece. Different foam molds can be used to form differently shaped front surfaces on the foam component. By this arrangement, different energy absorbing systems are provided for vehicles, such as to satisfy the need for different styling and shapes, while still using the same non-foam piece. By this arrangement, the energy absorber is a single unit that can be handled and attached to the bumper beam. At the same time, capital investment in molding dies and tooling is reduced.

Abstract: A rear body structure of a vehicle has a pair of first reinforcement members, second reinforcement members and third reinforcement members. The first members are provided from both edges of the roof to a front section of the pickup bed. Each first member is provided so that its front section lies along one of the edges of the roof while its rear section lies along one of the first pillars. The second members are provided on upper edges of side panels provided at both sides of the pickup bed from the front to rear ends of the pickup bed. Each second member is jointed, at the front end to one of the first members. Each second member is segmented into a first crushable zone and a second zone. The first zone is located behind the second zone and more fragile than the second zone against the load applied from behind the vehicle.

Abstract: A system and method for reinforcing at least a portion of a structural member, including at least one chamber or compartment having an interior portion which substantially conforms to the dimensions and geometry of the structural member being reinforced; and a reinforcement material for filling the interior portion of one or more of the compartments or chambers. The reinforcement material filling one or more of the compartments or chambers of the present invention can be a pumpable polymeric material, an heat activated expandable material, or a self-curing material. The compartment or chamber can be a polymeric material, such as nylon, which can be solid, blow-molded, flexible, or expandable depending upon the selected structural member to be reinforced.

Abstract: A system and method for reinforcing at least a portion of a structural member, including at least one hollow carrier, having an exterior shell and an interior portion, which substantially conforms to the dimensions and geometry of the structural member being reinforced; and a lightweight, low density material for filling the interior portion of one or more of the carriers. The material filling one or more of the carriers of the present invention can be a reinforcement material, self-curing material, or a heat activated expandable material. The carrier can be produced by blow molding or rotational molding and has an adhesive material disposed along at least a portion of the exterior shell used to place, adhere, and affix the carrier to a targeted portion of the structural member selected to be structurally reinforced.