Devices and methods for reinforcing hollow structural members

Abstract

Reinforcement devices ( 10, 10′, 110, 110′ ) may be inserted into a cavity ( 6 ) of a hollow structural member ( 1 ) in order to reinforce the hollow structural member ( 1 ). The reinforcement devices ( 10, 10′, 110, 110′ ) may include a first elongated reinforcement part ( 11, 111 ) having at least one mating surface ( 15 a , 17 a , 115 a ) extending along a longitudinal axis of the first part ( 11, 111 ) and a second elongated reinforcement part ( 12, 121 ) having at least one mating surface ( 25 a, 27 a, 125 a ) extending along a longitudinal axis of the second part ( 12, 121 ). An adhesive resin material preferably adheres the first elongated reinforcement part ( 11, 111 ) to the second elongated reinforcement part ( 12, 121 ). The adhesive resin material may comprise a thermosetting resin that thermosets when heated. Thus, a thermoset product ( 31, 136 ) will connect the reinforcement parts ( 11, 12, 111, 121 ) after heating. In addition or in the alternative, the adhesive resin material may comprise a foamable resin that foams when heated. Thus, a foamed product ( 31, 136 ) will connect the reinforcement parts ( 11, 12, 111, 121 ) after heating.

What is claimed is:  
     
         1 . An apparatus adapted to be inserted into a cavity of a hollow structural member and to reinforce the hollow structural member, comprising: 
 a first elongated reinforcement part having at least one mating surface extending along a longitudinal axis of the first elongated reinforcement part,    a second elongated reinforcement part having at least one mating surface extending along a longitudinal axis of the second elongated reinforcement part and    an adhesive resin material adhering the first elongated reinforcement part to the second elongated reinforcement part.    
     
     
         2 . An apparatus as defined in    claim 1   , wherein the adhesive resin material comprises an elongated connecting rod disposed between the mating surface of the first elongated reinforcement part and the mating surface of the second elongated reinforcement part.  
     
     
         3 . An apparatus as defined in    claim 1   , wherein the first elongated reinforcement part further comprises at least one flange extending along the longitudinal axis of the first elongated reinforcement part, the second elongated reinforcement part further comprises at least one flange extending along the longitudinal axis of the second elongated reinforcement part and the adhesive resin material comprises a fastener coupling the flanges.  
     
     
         4 . An apparatus as defined in    claim 3   , wherein the adhesive resin material further comprises an elongated connecting rod disposed between the mating surface of the first elongated reinforcement part and the mating surface of the second elongated reinforcement part.  
     
     
         5 . An apparatus as defined in    claim 4   , wherein the fastener is a clip.  
     
     
         6 . An apparatus as defined in    claim 5   , wherein the adhesive resin material comprises a thermosetting resin that thermosets when heated, wherein the first and second reinforcement parts will be connected by a thermoset product after heating.  
     
     
         7 . An apparatus as defined in    claim 5   , wherein the adhesive resin material comprises a foamable resin that foams when heated.  
     
     
         8 . An apparatus as defined in    claim 5   , wherein the adhesive resin material comprises a foamable, thermosetting resin that thermosets and foams when heated, wherein the reinforcement parts will be connected by a foamed, thermoset product after heating.  
     
     
         9 . An apparatus as defined in    claim 8   , wherein at least one of the first elongated reinforcement part or the second reinforcement part comprises a synthetic resinous material.  
     
     
         10 . An apparatus as defined in    claim 9   , wherein at least one of the first elongated reinforcement part or the second reinforcement part is a substantially light-weight hollow part that comprises at least one supplemental wall constructed to impart strength and rigidity to the first or second reinforcement part.  
     
     
         11 . An apparatus as defined in    claim 1   , wherein the adhesive resin material comprises a thermosetting resin that thermosets when heated.  
     
     
         12 . An apparatus as defined in    claim 1   , wherein the adhesive resin material comprises a foamable resin that foams when heated, wherein the reinforcement parts will be connected by a foamed product after heating.  
     
     
         13 . An apparatus as defined in    claim 1   , wherein the adhesive resin material comprises a foamable, thermosetting resin that thermosets and foams when heated, wherein the reinforcement parts will be connected by a foamed, thermoset product after heating.  
     
     
         14 . An apparatus as defined in    claim 13   , wherein at least one of the first elongated reinforcement part or the second reinforcement part comprises a synthetic resinous material.  
     
     
         15 . An apparatus as defined in    claim 13   , wherein at least one of the first elongated reinforcement part or the second reinforcement part is a substantially light-weight hollow part that comprises at least one supplemental wall constructed to impart strength and rigidity to the first or second reinforcement part.  
     
     
         16 . An apparatus as in    claim 13   , wherein the adhesive resin material has been heated to form the foamed, thermoset product.  
     
     
         17 . An apparatus as defined in    claim 1   , wherein the first elongated reinforcement part comprises at least two mating surfaces extending along the longitudinal axis of the first elongated reinforcement part, the second elongated reinforcement part comprises at least two mating surfaces extending along the longitudinal axis of the second elongated reinforcement part and the adhesive resin material comprises at least two elongated connecting rod disposed between the respective mating surfaces of the first elongated reinforcement part and the respective mating surfaces of the second elongated reinforcement part.  
     
     
         18 . An apparatus as defined in    claim 1   , wherein the adhesive resin material comprises an epoxy resin, a urethane or a phenol resin.  
     
     
         19 . An apparatus as defined in    claim 1   , wherein the adhesive resin material comprises (i) a co-polymer of epichlorohydrin and bisphenol A, (ii) a composition comprising phenol and formaldehyde, (iii) a composition comprising isocyanate and an alcohol or (iv) a composition comprising maleic anhydride, fumaric acid and glycol.  
     
     
         20 . An apparatus as defined in    claim 1   , wherein at least one of the first elongated reinforcement part or the second reinforcement part comprises a synthetic resinous material and at least one of the first elongated reinforcement part or the second reinforcement part is a substantially light-weight hollow part that comprises at least one supplemental wall constructed to impart strength and rigidity to the first or second reinforcement part, wherein at least one of the mating surfaces comprises grooves having an opening circumference that is less than an interior circumference, the adhesive resin material comprises a thermosetting, foamable resin, wherein a thermoset, foamed product is formed during the heating step and the thermoset, foamed product securely bonds the first and second reinforcement parts together by engaging a lip defined within the grooves and securely fits the first and second reinforcement parts within the cavity.  
     
     
         21 . A method for reinforcing a hollow structural member, comprising: 
 adhering at least two elongated reinforcement parts using an adhesive resin material, thereby forming an intermediate reinforcement device,    disposing the intermediate reinforcement device within a cavity defined within the hollow structural member and    applying external heat to the reinforcement device.    
     
     
         22 . A method as defined in    claim 21   , wherein the adhesive resin material comprises a thermosetting resin, wherein a thermoset product is formed during the heating step and the thermset product securely bonds the at least two reinforcement parts.  
     
     
         23 . A method as defined in    claim 21   , wherein the adhesive resin material comprises a foamable resin, wherein a foamed product is formed during the heating step and the foamed product securely fits the at least two reinforcement products within the cavity.  
     
     
         24 . A method as defined in    claim 21   , wherein the adhesive resin material comprises a thermosetting, foamable resin, wherein a thermoset, foamed product is formed during the heating step and the thermoset, foamed product securely bonds the at least two reinforcement parts together and securely fits the at least two reinforcement products within the cavity.  
     
     
         25 . A method as defined in    claim 21   , wherein the adhesive resin material comprises an epoxy resin, a urethane or a phenol resin.  
     
     
         26 . A method as defined in    claim 21   , wherein the adhesive resin material comprises (i) a co-polymer of epichlorohydrin and bisphenol A, (ii) a composition comprising phenol and formaldehyde, (iii) a composition comprising isocyanate and an alcohol or (iv) a composition comprising maleic anhydride, fumaric acid and glycol.  
     
     
         27 . A method as defined in    claim 21   , wherein the at least two elongated reinforcement parts each comprise at least one flange extending along a longitudinal axis of the elongated reinforcement part and the adhesive resin material comprises a fastener coupling the flanges.  
     
     
         28 . A method as defined in    claim 27   , wherein the at least two elongated reinforcement parts each comprise at least mating surface extending along a longitudinal axis of the elongated reinforcement part, wherein the adhesive resin material further comprises an elongated connecting rod disposed between the mating surfaces of the at least two elongated reinforcement parts.  
     
     
         29 . A method as defined in    claim 28   , wherein the fastener is a clip.  
     
     
         30 . A method as defined in    claim 29   , wherein at least one of the mating surfaces comprises grooves having an opening circumference that is less than an interior circumference, the adhesive resin material comprises a thermosetting, foamable resin, wherein a thermoset, foamed product is formed during the heating step and the thermoset, foamed product securely bonds the at least two reinforcement parts together by engaging a lip defined within the grooves and securely fits the at least two reinforcement parts within the cavity.  
     
     
         31 . A method as defined in    claim 21   , wherein the at least two elongated reinforcement parts each comprise at least mating surface extending along a longitudinal axis of the elongated reinforcement part, wherein the adhesive resin material comprises an elongated connecting rod disposed between the mating surfaces of the at least two elongated reinforcement parts.  
     
     
         32 . A method as defined in    claim 31   , wherein the adhesive resin material comprises a thermosetting, foamable resin and wherein a thermoset, foamed product is formed during the heating step and the thermoset, foamed product securely bonds the at least two reinforcement parts together and securely fits the at least two reinforcement products within the cavity.  
     
     
         33 . A method as defined in    claim 32   , wherein at least one elongated reinforcement part comprises a synthetic resinous material.  
     
     
         34 . A method as defined in    claim 33   , wherein at least one elongated reinforcement part is a substantially light-weight hollow part that comprises at least one supplemental wall constructed to impart strength and rigidity to the at least one elongated reinforcement part.  
     
     
         35 . An apparatus ( 10 ,  10 ′,  110 ,  110 ′) disposed within a cavity ( 6 ) of a hollow structural member ( 1 ) in order to reinforce the hollow structural member ( 1 ) comprising: 
 a first elongated reinforcement part ( 11 ,  111 ) having at least one mating surface ( 15   a ,  17   a ,  115   a ) extending along a longitudinal axis of the first part ( 11 ,  111 ),  
 a second elongated reinforcement part ( 21 ,  121 ) having at least one mating surface ( 25   a ,  27   a ,  125   a ) extending along a longitudinal axis of the second part ( 21 ,  121 ), wherein at least one of the first elongated reinforcement part ( 11 ,  111 ) or the second reinforcement part ( 12 ,  121 ) comprises a synthetic resinous material and wherein at least one of the first elongated reinforcement part ( 11 ,  111 ) or the second reinforcement part ( 21 ,  121 ) is a substantially light-weight hollow part that comprises at least one supplemental wall ( 15 ,  25 ,  115 ,  125 ) constructed to impart strength and rigidity to the part ( 11 ,  21 ,  111 ,  121 ) and  
 at least one elongated connecting rod ( 30 ,  130 ) adhering the mating surface ( 15   a ,  17   a ,  115   a ) extending along the longitudinal axis of the first elongated reinforcement part ( 11 ,  111 ) to the mating surface ( 25   a ,  27   a ,  125   a ) extending along the longitudinal axis of the second elongated reinforcement part ( 21 ,  121 ), wherein the at least one elongated connecting rod ( 30 ,  130 ) comprises a thermosetting, foamable resin and wherein a thermoset, foamed product is formed upon heating and the thermoset, foamed product will bonds the first elongated reinforcement part ( 11 ,  111 ) to the second elongated reinforcement part ( 21 ,  121 ) and will fit the first elongated reinforcement part ( 11 ,  111 ) and the second elongated reinforcement part ( 21 ,  121 ) within the cavity ( 6 ).  
 
     
     
         36 . An apparatus as in    claim 35   , wherein the mating surface ( 15   a ,  17   a ,  115   a ) extending along the longitudinal axis of the first elongated reinforcement part ( 11 ,  111 ) and the mating surface ( 25   a ,  27   a ,  125   a ) extending along the longitudinal axis of the second elongated reinforcement part ( 21 ,  121 ) each comprise grooves ( 13 ,  23 ) having an opening circumference that is less than an interior circumference, wherein the thermoset, foamable product will engage a lip ( 23   a ) defined within the grooves ( 13 ,  23 ).  
     
     
         37 . An apparatus as in    claim 36   , wherein the mating surfaces ( 15   a ,  17   a ,  25   a ,  27   a ,  115   a ,  125   a ) are roughened.  
     
     
         38 . An apparatus as defined in    claim 37   , wherein the first elongated reinforcement part ( 111 ) further comprises at least one flange ( 116 ) extending along the longitudinal axis of the first part ( 111 ), the second elongated reinforcement part ( 121 ) further comprises at least one flange ( 126 ) extending along the longitudinal axis of the second part ( 121 ) and a fastener ( 132 ,  135 ) couples the flanges ( 116 ,  126 ).  
     
     
         39 . An apparatus as defined in    claim 38   , wherein the fastener comprises a thermosetting, foamable resin.  
     
     
         40 . A apparatus as defined in    claim 39   , wherein the adhesive resin material comprises (i) a co-polymer of epichlorohydrin and bisphenol A, (ii) a composition comprising phenol and formaldehyde, (iii) a composition comprising isocyanate and an alcohol or (iv) a composition comprising maleic anhydride, fumaric acid and glycol.