Member for reinforcing, sealing or baffling and reinforcement system formed therewith

Abstract

A member is provided for reinforcing, sealing or baffling structures of articles of manufacture such as automotive vehicles. The member typically includes a carrier member that is typically at least partially formed of a metal. The member also typically includes an expandable material disposed on the carrier member.

1 . A process for reinforcing, sealing or baffling a structure of an article of manufacture, the process comprising: 
 forming a metal material into a carrier, the metal material including aluminum, magnesium or a combination thereof;    applying an expandable material to the carrier to form a member;    inserting the member within a cavity of the structure; and    activating the expandable material to expand, contact and wet internal walls of the cavity of the structure of the article of manufacture and to adhere the member within cavity.    
   
   
       2 . A process as in  claim 1  wherein the forming of the metal material includes shaping of a slurry of spherical or otherwise shaped solid particles in a liquid metal matrix.  
   
   
       3 . A process as in  claim 1  wherein the forming of the metal material includes a thixomolding process.  
   
   
       4 . A process as in  claim 1  wherein the structure is part of an automotive vehicle.  
   
   
       5 . A process as in  claim 1  wherein the metal material of the carrier is at least 85% metal.  
   
   
       6 . A process as in  claim 1  wherein the carrier member has an outer surface that is roughened or textured for allowing the expandable material to adhere to a surface of the carrier with greater strength.  
   
   
       7 . A process as in  claim 1  wherein the shape of the carrier corresponds to the shape of the cavity of the structure.  
   
   
       8 . A process as in  claim 1  wherein the expandable material is activated at a temperature experienced in an e-coat or paint oven.  
   
   
       9 . A process for reinforcing a structure of an automotive vehicle, the process comprising: 
 forming a metal material into a carrier, the metal material including aluminum, magnesium or a combination thereof, the forming of the carrier including: 
 i. forming metal masses into a slurry of solid particles in a liquid metal matrix;  
 ii. feeding the slurry within a cavity of a mold;  
 iii. solidifying the slurry within the mold to form the carrier into a desired shape  
   applying an expandable material to the carrier to form a reinforcement member;    inserting the member within a cavity of the structure; and    activating the expandable material to expand, contact and wet internal walls of the cavity of the structure of the article of manufacture and to adhere the member within cavity.    
   
   
       10 . A process as in  claim 9  wherein the solid particles or internally hollow for forming a cellular carrier member.  
   
   
       11 . A process as in  claim 9  wherein the mold is at a temperature of about 150° C. to abut 400° C.  
   
   
       12 . A process as in  claim 9  wherein the mold is at a temperature of about 200° 0  C. to abut 250° C.  
   
   
       13 . A process as in  claim 9  wherein the forming of the metal masses into a slurry involve feeding the metal masses to a machine having a molding barrel and screw for at least partially melting the metal masses.  
   
   
       14 . A process as in  claim 9  wherein the forming of the metal material includes shaping of a slurry of spherical or otherwise shaped solid particles in a liquid metal matrix.  
   
   
       15 . A process as in  claim 9  wherein the forming of the metal material includes a thixomolding process.  
   
   
       16 . A process as in  claim 9  wherein the structure is part of an automotive vehicle.  
   
   
       17 . A process as in  claim 9  wherein the metal material of the carrier is at least 85% metal.  
   
   
       18 . A process as in  claim 9  wherein the carrier member has an outer surface that is roughened or textured for allowing the expandable material to adhere to a surface of the carrier with greater strength.  
   
   
       19 . A process as in  claim 9  wherein the shape of the carrier corresponds to the shape of the cavity of the structure.  
   
   
       20 . A process as in  claim 9  wherein the expandable material is activated at a temperature experienced in an e-coat or paint oven.