Insertable barrier and chamber system for reinforcement of structural members

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.

What is claimed is:  
     
         1 . A reinforced portion of an automotive vehicle, comprising: 
 a) an automotive vehicle structural member having a wall structure that defines a cavity; and    b) a reinforcement that includes: 
 i) a barrier layer that is conformably adhered to the wall structure after thermal activation at a temperature in the range of 93.33° C. or higher; and  
 ii) a polymeric foam reinforcement material located within and adhered to the barrier.  
   
     
     
         2 . A reinforced portion of an automotive vehicle according to  claim 1 , further comprising mechanical retention means to attach the reinforcement to the structural member.  
     
     
         3 . A reinforced portion of an automotive vehicle according to  claim 1 , wherein the reinforced portion is an automotive frame or rail.  
     
     
         4 . A reinforced portion of an automotive vehicle according to  claim 1 , wherein the structural member is a portion of an automotive pillar.  
     
     
         5 . A reinforced portion of an automotive vehicle according to  claim 1 , wherein the polymeric foam reinforcement material a structural foam.  
     
     
         6 . A reinforced portion of an automotive vehicle according to  claim 1 , wherein the polymeric foam reinforcement material is an epoxy.  
     
     
         7 . A reinforced portion of an automotive vehicle according to  claim 1 , wherein the polymeric foam reinforcement material is a polyurethane.  
     
     
         8 . A reinforced portion of an automotive vehicle according to  claim 1 , wherein the barrier is an injection molded form.  
     
     
         9 . A reinforced portion of an automotive vehicle according to  claim 1 , wherein the barrier is an extruded form.  
     
     
         10 . A reinforced portion of an automotive vehicle according to  claim 9 , wherein the barrier is extruded and die cut in accordance with a predetermined configuration.  
     
     
         11 . A reinforced portion of an automotive vehicle according to  claim 1 , wherein the barrier partially encapsulates the structural foam.  
     
     
         12 . A reinforced portion of an automotive vehicle, comprising: 
 a) an automotive vehicle structural member having a wall structure that defines a cavity;    b) a reinforcement that includes: 
 i) an extruded and die-cut barrier layer that is conformably adhered to the wall structure after thermal activation at a temperature in the range of 93.33° C. or higher; and  
 ii) a polymeric structural foam reinforcement material partially encapsulated within and adhered to the barrier; and  
   c) mechanical retention means to attach the reinforcement to the structural member.    
     
     
         13 . A reinforced portion of an automotive vehicle according to  claim 12 , wherein the barrier layer includes a foam.  
     
     
         14 . A reinforced portion of an automotive vehicle according to  claim 12 , wherein the barrier layer includes an epoxy.  
     
     
         15 . A reinforced portion of an automotive vehicle according to  claim 14 , wherein the structural foam reinforcement material is an epoxy.  
     
     
         16 . A reinforced portion of an automotive vehicle according to  claim 14 , wherein the structural foam reinforcement material is a polyurethane.  
     
     
         17 . A reinforced portion of an automotive vehicle according to  claim 12 , wherein the barrier layer includes a port.  
     
     
         18 . A method of reinforcing an automotive pillar comprising of the following steps: 
 providing an automotive pillar having an interior cavity;    inserting a foam polyurethane core having an encapsulating heat activated expandable barrier into a portion of an automotive pillar; and    heating the automotive pillar to a temperature in the range of 93.33° C. or higher such that the heat activated expandable barrier conforms in shape and adheres to the interior cavity of the automotive pillar.    
     
     
         19 . The method of  claim 18 , further comprising the step of using one or more mechanical retainers for placing the foam polyurethane core having an encapsulating heat activated expandable barrier into the automotive pillar.  
     
     
         20 . The method of  claim 18 , wherein the heat activated expandable barrier is configured with one or more perforations.