Structural reinforcements

Patent metadata

Field	Value
Publication number	US-9415811-B2
Application number	US-201414179615-A
Country	US
Kind code	B2
Filing date	Feb 13, 2014
Priority date	Jul 25, 2006
Publication date	Aug 16, 2016
Grant date	Aug 16, 2016

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.

First claim

What is claimed is:

1. A reinforcement system, for a structural member, the system comprising:
a carrier formed of a combination of polymeric and metallic materials having a length extending between a first end and a second end, the carrier including one or more sidewalls joined together to form one or more cavities extending along the length of the carrier, the carrier including a cross-sectional shape roughly corresponding to the cross-sectional shape of interior walls of a hollow structural member;
a plurality of restrictors integrally formed with and extending from the carrier;
an activatable material placed over the carrier, the activatable material configured to expand upon application of heat and adhere to the interior walls of the hollow structural member to provide reinforcement to the same;
wherein the restrictors allow for placing and locating of the activatable material relative to the carrier without the use of additional fasteners; and
wherein one or more ribs are formed within projections extending from an end cap on the first end, the second end, or both ends of the reinforcement system.

2. The reinforcement system of claim 1 , wherein the one or more cavities are formed of the carrier sidewalls and include a top wall and side walls integrally formed with the carrier to form a unitary structure.

3. The reinforcement system of claim 1 , further comprising one or more attachment feature and wherein the one or more attachment feature allow for attaching the reinforcement system to the interior walls of the hollow structural member.

4. The reinforcement system of claim 3 , wherein the attachment feature is located at an end of the reinforcement system.

5. The reinforcement system of claim 3 , wherein the attachment feature is a locator integrally formed with the carrier of the reinforcement system.

6. The reinforcement system of claim 3 , wherein the attachment feature is a mechanical fastener.

7. The reinforcement system of claim 3 , wherein the attachment feature is not integrally formed with the metallic material of the reinforcement system.

8. The reinforcement system of claim 7 , wherein the attachment feature extends through a metallic material of the reinforcement system.

9. The reinforcement system of claim 1 , wherein the cavities are consecutively arranged along a height or width of the carrier.

10. The reinforcement system of claim 1 , wherein the metallic material is selected from steel, aluminum, magnesium, an alloy, or any combination thereof.

11. The reinforcement system of claim 1 , wherein the carrier is formed by injection molding.

12. The reinforcement system of claim 1 , wherein the activatable material is located onto the carrier having a substantially uniform thickness prior to expansion.

13. The reinforcement system of claim 1 , wherein the reinforcement system includes one or more apertures for locating the carrier within the hollow structural member.

14. The reinforcement system of claim 1 , wherein the carrier includes one or more through-holes.

15. The reinforcement system of claim 1 , wherein one or more ends are integrally formed with the carrier.

16. The reinforcement system of claim 1 , wherein the carrier and one or more ends are polymeric.

17. The reinforcement system of claim 1 , including an attachment feature integrally formed with the carrier.

Assignees

• Zephyros Inc

Inventors

• Schneider Dean J
• Bolton Joseph L

Classifications

• E04C3/29

  built-up from parts of different material, {i.e. composite structures} · CPC title

• Y10T428/13

  Hollow or container type article [e.g., tube, vase, etc.] · CPC title

• B29C44/18

  Filling preformed cavities {(B29C44/1204 takes precedence)} · CPC title

• B29C44/128

  Internally reinforcing constructional elements, e.g. beams · CPC title

• Y10T428/233

  Foamed or expanded material encased · CPC title