Multiple stage deformation reinforcement structure for impact absorption

Abstract

A structural reinforcement for a vehicle comprising: a) a carrier having a base wall from which a plurality of projections extend, the plurality of projections including at least one first projection and at least one second projection and the at least one first projection having a height greater than a height of the at least one second projection; b) an activatable material which is heat activatable and affixed to the carrier, configured to secure the carrier in a cavity of the vehicle; wherein in event of an impact, the at least one first projection and second projection are configured to deform toward the base wall and/or in a direction of an impact load in response to the impact load; and the at least one first projection is configured to receive the impact load and deform before the at least one second projection receives the impact load and deforms.

1 . A structural reinforcement for a vehicle adapted to reinforce a cavity of an automotive vehicle, the cavity being defined by a spaced apart first panel and a second panel, and an intermediate panel that has an opening through it and that is located between the first panel and the second panel, the structural reinforcement comprising:
 (a) a carrier having:
 (i) a base wall; 
 (ii) a first set of projections extending generally orthogonally along their length from the base wall; 
 (iii) a second set of projections extending generally orthogonally from the base wall wherein a height of the first set of projections relative to the base wall is greater than a height of the second set of projections relative to the base wall; 
 (iv) one or more ownings extending through the base wall between the first set of projections or the second set of projections, w herein the first set of projections are adapted to or more openings of the carrier remain exposed through the opening of the intermediate panel to allow fluid to flow through the cavity and the structural reinforcement; and 
 (v) a least one fastener located along the carrier that is adapted to affix the structural reinforcement to a vehicle structure; and 
   (b) an activatable material affixed to at least a portion of the carrier.   
     
     
         2 - 20 . (canceled) 
     
     
         21 . The structural reinforcement of  claim 1 , wherein the at least one fastener is integrally formed with the carrier or formed separate from the carrier and affixed to the carrier. 
     
     
         22 . The structural reinforcement of  claim 21 , wherein the first set of projections and the second set of projections extend from the base wall in the same direction. 
     
     
         23 . The structural reinforcement of  claim 22 , wherein the second set of projections form a cell-like structure and the one or more openings of the carrier are positioned in the cell-like structure. 
     
     
         24 . The structural reinforcement of  claim 23 , wherein the first set of projections form a cell-like structure. 
     
     
         25 . The structural reinforcement of  claim 24 , wherein the at least one fastener is a snap-fit fastener located on a periphery of the first set of projections that is adapted to engage an edge surface of the opening of the intermediate panel. 
     
     
         26 . The structural reinforcement of  claim 25 , wherein the first set of projections is located adjacent to the second set of projections and within the confines of the carrier formed by an outer perimeter of the carrier. 
     
     
         27 . The structural reinforcement of  claim 26 , wherein the activatable material is located on both the first set of projections and the second set of projections. 
     
     
         28 . The structural reinforcement of  claim 27 , wherein the activatable material at least partially surrounds a perimeter of the second set of projections. 
     
     
         29 . The structural reinforcement of  claim 28 , wherein the cavity includes a first cavity and a second cavity, and the first cavity and the second cavity are separated by the intermediate panel; and
 wherein the first set of projections define a first portion that is configured upon installation to project through the intermediate panel toward and into the first cavity so that the first portion reinforces the first cavity.   
     
     
         30 . The structural reinforcement of  claim 29 , wherein the first set of projections and the second set of projections are configured, upon installation, to extend substantially orthogonal to the intermediate panel. 
     
     
         31 . The structural reinforcement of  claim 30 , wherein the at least one fastener is integrally formed with the first set of projections. 
     
     
         32 . The structural reinforcement of  claim 31 , wherein a portion of the activatable material located on the second set of projections is substantially C-shaped. 
     
     
         33 . The structural reinforcement of  claim 32 , wherein a thickness of the base wall is different than a thickness of one or more projections of the first set of projections, a thickness of the base wall is different than a thickness of one or more projections of the second set of projections, or both. 
     
     
         34 . A structural reinforcement for a vehicle adapted to reinforce a cavity of an automotive vehicle, the cavity being defined by a spaced apart first panel and a second panel, and an intermediate panel that has an opening through it and that is located between the first panel and the second panel, the structural reinforcement comprising:
 (a) a carrier having:
 (i) a base wall; 
 (ii) a first set of projections extending generally orthogonally along their length from the base wall; 
 (iii) a second set of projections extending generally orthogonally from the base wall, wherein a height of the first set of projections relative to the base wall is greater than a height of the second set of projections relative to the base wall; 
 (iv) one or more openings extending through the base wall between the first set of projections or the second set of projections; and 
 (v) a least one fastener integrally formed with the carrier or formed separate from the carrier and affixed to the carrier, wherein the at least one fastener is configured to affix the structural reinforcement to a vehicle structure; 
   (b) an activatable foam material affixed to at least a portion of the carrier, wherein the activatable foam material is adapted for structural reinforcement, acoustical insulation, or both; and   (c) an activatable sealant material affixed to at least a portion of the carrier.   
     
     
         35 . The structural reinforcement of  claim 34 , wherein the activatable foam material is located on the first set of projections, the second set of projections, or both. 
     
     
         36 . The structural reinforcement of  claim 35 , wherein the activatable sealant material at least partially surrounds a perimeter of the second set of projections. 
     
     
         37 . The structural reinforcement of  claim 36 , wherein the first set of projections form a first portion and the second set of projections form a second portion, and the first portion is located within the confines of the second portion formed by an outer perimeter of the second portion. 
     
     
         38 . The structural reinforcement of  claim 37 , wherein the outer perimeter of the second portion forms an outer perimeter of the carrier. 
     
     
         39 . A structural reinforcement for a vehicle adapted to reinforce a cavity of an automotive vehicle, the cavity having one or more panels and the structural reinforcement comprising:
 (a) a carrier having:
 (i) a base wall; 
 (ii) a first set of projections extending generally orthogonally along their length from the base wall; 
 (iii) a second set of projections extending generally orthogonally from the base wall, wherein a height of the first set of projections relative to the base wall is greater than a height of the second set of projections relative to the base wall; 
 (iv) one or more openings extending through the base wall between the first set of projections or the second set of projections, wherein the first set of projections are adapted to have a smaller cross-sectional area than an opening of the cavity located on the one or more panels of the cavity so that the one or more openings of the carrier remain exposed through the opening of the cavity to allow fluid to flow through the cavity and the structural reinforcement; and 
 (v) a least one snap-fit fastener located on a periphery of the first set of projections that is adapted to engage an edge surface of the opening of the cavity; 
   (b) an activatable foam material affixed to at least a portion of the carrier that is adapted for structural reinforcement and acoustical insulation; and   (c) an activatable sealant material affixed to at least a portion of the carrier.