Structural reinforcement system

Patent metadata

Field	Value
Publication number	US-9555840-B2
Application number	US-200913058718-A
Country	US
Kind code	B2
Filing date	Aug 12, 2009
Priority date	Aug 12, 2008
Publication date	Jan 31, 2017
Grant date	Jan 31, 2017

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, a bonding material, and an insert. The rigid carrier provides the primary structural reinforcement within the cavity, and also serves as a substrate to carry the bonding material. The insert is provided to increase the structural rigidity of the reinforcement system.

First claim

We claim:

1. A structural reinforcement comprising:
i) an elongated rigid carrier having a longitudinal axis;
ii) an expandable material at least partially associated with the rigid carrier; and
iii) an insert aligned generally parallel with the longitudinal axis and located within a contemplated impact deformation region of the rigid carrier, wherein the insert is made of a material that is dissimilar from and has a higher tensile strength than the material of the rigid carrier so that upon impact in the impact deformation region the severity of deformation is reduced as compared to a part without the insert;
wherein the elongated rigid carrier and the insert are present in a cavity defined by a plurality of cavity walls, wherein the elongated rigid carrier and the insert are arranged in the cavity such that the insert is not in direct contact with any of the cavity walls.

2. The structural reinforcement of claim 1 , wherein the insert includes a fastening mechanism that fastens the insert to a vehicle structure or to the rigid carrier.

3. The structural reinforcement of claim 1 , wherein the insert is made of a metallic material.

4. The structural reinforcement of claim 1 , wherein the insert is substantially covered by the rigid carrier, the expandable material, or both.

5. The structural reinforcement of claim 1 , wherein the insert is a composite material.

6. The structural reinforcement of claim 1 , wherein the insert has an outer surface and at least a portion of the outer surface is in contact with the expandable material after expansion.

7. A structural reinforcement comprising:
i) an elongated rigid carrier having a longitudinal axis, a curved first surface, and including one or more ribs;
ii) an expandable material at least partially associated with the rigid carrier, wherein the expandable material is located adjacent to the one or more ribs; and
iii) an insert, made of a material that is dissimilar from the material of the rigid carrier, aligned generally parallel with the longitudinal axis and located within a contemplated impact deformation region of the rigid carrier, wherein the elongated rigid carrier and the insert are present in a cavity defined by a plurality of cavity such that the insert is not in direct contact with any of the cavity walls;
iv) wherein the ductility of the rigid carrier is greater than the ductility of the insert.

8. The structural reinforcement of claim 7 , wherein the insert has a generally curved or U-shaped profile.

9. The structural reinforcement of claim 7 , wherein the rigid carrier is a metal part, a composite part, a polymeric part, or any combination thereof.

10. The structural reinforcement of claim 7 , wherein the insert has one or more visible exposed surfaces after expansion of the expandable material.

11. The structural reinforcement of claim 7 , wherein the rigid carrier, the insert, or both, has a mechanical fastener.

12. A structural reinforcement comprising:
i) a rigid carrier including a curved first surface and one or more ribs;
ii) an expandable material at least partially associated with the rigid carrier, wherein the expandable material is located adjacent to the one or more ribs;
iii) an insert having a generally curved or U-shaped profile and located within a contemplated impact deformation region of the structural reinforcement, wherein:
a. the insert is made of a material that is dissimilar from the material of the rigid carrier;
b. the ductility of the rigid carrier is greater than the ductility of the insert;

iv) a fastening mechanism that fastens at least one of the rigid carrier and the insert to a vehicle structure,
wherein the rigid carrier and the insert are present in a cavity defined by a plurality of cavity walls, wherein the rigid carrier and the insert are arranged in the cavity such that the insert is not in direct contact with any of the cavity walls.

13. The structural reinforcement of claim 3 , wherein said metallic material is steel and/or aluminum.

14. The structural reinforcement of claim 7 , wherein one or more ribs are configured to direct the expansion of the expandable material toward a surface of a vehicle structure.

15. The structural reinforcement of claim 12 , wherein one or more ribs are configured to direct the expansion of the expandable material toward a surface of a vehicle structure.

16. The structural reinforcement of claim 1 , further comprising a second insert, wherein the second insert is arranged in the cavity such that the second insert is not in direct contact with the first insert or any of the cavity walls.

17. The structural reinforcement of claim 1 , wherein the insert is a fiber mat.

18. The structural reinforcement of claim 17 , wherein the fiber mat is shaped to substantially conform to the shape of the cavity.

Assignees

• Belpaire Vincent
• Mellano Dominique
• Vandenberg Yves
• Sika Tech Ag

Inventors

• Belpaire Vincent
• Mellano Dominique
• Vandenberg Yves

Classifications

• B62D25/025

  Side sills thereof · CPC title

• B62D29/001 Primary

  characterised by combining metal and synthetic material · CPC title

• B62D29/00

  Superstructures, {understructures, or sub-units thereof,} characterised by the material thereof {(B62D33/044, B62D33/048 take precedence)} · CPC title

• B62D29/002 Primary

  a foamable synthetic material or metal being added in situ (shaping of substances in a plastic state by foaming, in general B29C44/00) · CPC title

• B62D29/005

  preformed metal and synthetic material elements being joined together, e.g. by adhesives · CPC title