Method of forming a structural member

Abstract

The present invention relates to a method of forming a reinforced hollow member. The method comprises the step of inserting a structural reinforcement insert into a hollow member. The structural reinforcement insert is then positioned in the hollow member such that the structural reinforcement insert and hollow member define at least one fluid passageway. A structural adhesive is applied in the fluid passageway to lock the structural reinforcement insert in the hollow member.

What is claimed is:  
     
         1 . A method of forming a foam filled hollow member comprising: 
 inserting a structural reinforcement insert into the hollow member;    positioning the insert in the hollow member such that the insert and hollow member define at least one fluid passageway;    applying a structural adhesive in the fluid passageway to lock the insert in the hollow member.    
     
     
         2 . The method of  claim 1  further comprising the use of a non-expandable structural adhesive.  
     
     
         3 . The method of  claim 1  further comprising performing an E-coating process and draining the E-coating fluids through the fluid passageway.  
     
     
         4 . The method of  claim 2  further comprising heating the structural adhesive.  
     
     
         5 . The method of  claim 2  further comprising applying the structural adhesive as a liquid into the passageway.  
     
     
         6 . The method of  claim 2  further comprising applying the structural adhesive as a paste into the passageway.  
     
     
         7 . The method of  claim 2  further comprising utilizing a one component epoxy as the structural adhesive.  
     
     
         8 . The method of  claim 2  further comprising utilizing a two component epoxy as the structural adhesive.  
     
     
         9 . The method of  claim 2  further comprising utilizing a foam as the structural reinforcement insert.  
     
     
         10 . The method of  claim 9  further comprising placing a shell about the foam to form the structural reinforcement insert.  
     
     
         11 . The method of  claim 9  further comprising selecting the foam from the group comprising polyurethane, polyisocyanurate and hybrid foam.  
     
     
         12 . The method of  claim 1  further comprising positioning the insert by placing a locating pin on the insert in an opening in the hollow member.