Structural reinforcement system for automotive vehicles

Abstract

An automotive vehicle frame reinforcement system has a skeleton member designed to be secured to a vehicle frame, such as a roof or pillar section. An expandable material, such as an epoxy-based reinforcing foam, is disposed on the skeleton member. Once the system is attached to the frame, the foam expands and cures during an automobile assembly operation, bonding the reinforcement system to the frame. As a result, the reinforcement system provides enhanced load distribution over the vehicle frame without adding excessive weight.

1 - 21 . (canceled)  
   
   
       22 . A method of forming a reinforcement member for reinforcing a structure of an automotive vehicle, the method comprising: 
 molding a plastic skeleton member with a plurality of ribs wherein at least two ribs of the plurality of ribs are spaced apart from and opposing each other or wherein at least two ribs of the plurality of ribs intersect each other;    adhering a foamable structural reinforcement material to the skeleton member to form a reinforcement member, wherein:    i. the foamable structural reinforcement material includes a blowing agent and a curing agent and is substantially tack free to the touch;    ii. the foamable structural reinforcement material is configured to activate to foam and cure upon exposure to an elevated temperature experienced in an automotive assembly operation; and    iii. the skeleton member is shaped to correspond to a cavity that is defined by a structure of an automotive vehicle, the structure being selected from a pillar, a roof rail, a frame member or a combination thereof.    
   
   
       23 . A method as in  claim 22  wherein the reinforcement member includes one or more mechanical fasteners for at least temporarily locating the reinforcement member within the cavity prior to activation of the reinforcement material.  
   
   
       24 . A method as in  claim 22  wherein the skeleton member includes an opening suitable for passage of a component therethrough.  
   
   
       25 . A method as in  claim 22  wherein the structure is an A-pillar.  
   
   
       26 . A method as in  claim 22  wherein the curing includes cross-linking of the reinforcement material and the reinforcement material includes a phenoxy material and wherein the plastic skeleton member is nylon.  
   
   
       27 . A method as in  claim 22  wherein the plurality of ribs are beam-like in function for strengthening the member.  
   
   
       28 . A method as in  claim 22  wherein the reinforcement material is configured to distribute loads over a surface of the skeleton member and at least one rib of the plurality of ribs is in non-parallel relationship to the surface over which the loads are to be distributed.  
   
   
       29 . A method as in  claim 22  wherein the member is such that, over at least one half of the member, the cross-sectional area of the member is less than 50% of the a silhouette profile of the member.  
   
   
       30 . A method as in  claim 22  wherein the skeleton member exhibits a weight reduction of 70% as compared to a solid structure of the same material.  
   
   
       31 . A method as in  claim 22  wherein the structure is a lower rail of the vehicle.  
   
   
       32 . A method as in  claim 22  wherein the skeleton member includes a first longitudinal outwardly facing surface opposite a second outward facing longitudinal surface and wherein both the first surface and the second surfaces support reinforcement material and the at least two of the plurality of ribs adjoin the first surface, the second surface or both.  
   
   
       33 . A method as in  claim 22  wherein the skeleton members includes the intersecting ribs, which include at least one laterally extending rib and at least one longitudinally extending rib.  
   
   
       34 . A method as in  claim 22  wherein the at least two ribs are substantially devoid of the reinforcement material.  
   
   
       35 . A method as in  claim 22  wherein the step of adhering the reinforcement material includes molding the reinforcement material upon the skeleton member.  
   
   
       36 . A method as in  claim 22  wherein the skeleton member and the structural material are configured to cooperatively seal the cavity to block passage of materials through the cavity.  
   
   
       37 . A method of forming a reinforcement member for reinforcing a structure of an automotive vehicle, the method comprising: 
 injection molding a plastic skeleton member with a plurality of ribs wherein at least two ribs of the plurality of ribs are spaced apart from each other along a length of the skeleton member and opposing each other and wherein at least two ribs of the plurality of ribs intersect each other;    molding and adhering a foamable structural reinforcement material to the skeleton member to form a reinforcement member, wherein:    i. the foamable structural reinforcement material includes an epoxy resin, a blowing agent and a curing agent and is substantially tack free to the touch;    ii. the foamable structural reinforcement material is configured to activate to foam and cure upon exposure to an elevated temperature experienced in an automotive assembly operation; and    iii. the skeleton member is shaped to correspond to a cavity that is defined by a structure of an automotive vehicle, the structure being selected from a pillar, a roof rail, a frame member or a combination thereof.    
   
   
       38 . The method of  claim 37  wherein the skeleton member includes one or more extensions extending therefrom and wherein the skeleton member includes an opening suitable for passage of a component therethrough and wherein the structure is a lower rail of the vehicle.  
   
   
       39 . A method as in  claim 37  wherein the reinforcement member includes one or more mechanical fasteners for at least temporarily locating the reinforcement member within the cavity prior to activation of the reinforcement material and wherein the curing includes cross-linking of the reinforcement material and the reinforcement material includes a phenoxy material and wherein the plastic skeleton member is nylon and.  
   
   
       40 . A method as in  claim 37  wherein the plurality of ribs are beam-like in function for strengthening the member and wherein the reinforcement material is configured to distribute loads over a surface of the skeleton member and at least one rib of the plurality of ribs is in non-parallel relationship to the surface over which the loads are to be distributed  
   
   
       41 . A method as in  claim 37  wherein the member is such that, over at least one half of the member, the cross-sectional area of the member is less than 50% of the a silhouette profile of the member and wherein the skeleton member exhibits a weight reduction of 70% as compared to a solid structure of the same material.  
   
   
       42 . A method as in  claim 37  wherein the skeleton member includes a first longitudinal outwardly facing surface opposite a second outward facing longitudinal surface and wherein both the first surface and the second surfaces support reinforcement material and the at least two of the plurality of ribs adjoin the first surface, the second surface or both.  
   
   
       43 . A method as in  claim 37  wherein the skeleton members includes the intersecting ribs, which include at least one laterally extending rib and at least one longitudinally extending rib and wherein the at least one laterally extending rib and the at least one longitudinally extending rib of the first portion and are substantially devoid of the foam.