Reinforcement structure and method employing bulkheads

摘要

A structural reinforcement device for insertion into a cavity of a structure and method for making the same including a first reinforcement section that has at least one projection of a first expandable polymeric material secured to it; and a separate second reinforcement section mated with the first reinforcement section, the second reinforcement section being configured to include at least one cavity, into which the at least one projection penetrates upon mating, and at least one aperture defined therein through which the expandable material flows during expansion and where it will remain upon curing of the material, thereby causing the first reinforcement section to be coupled with the second reinforcement section.

主权项

1. A method for manufacturing a structural reinforcement device for insertion into a vehicle cavity of a structure, comprising the steps of:
a) providing a first reinforcement section having a first side and a generally opposing second side that has at least one projection formed of a first expandable polymeric material and secured to the generally opposing second side; b) mating the first reinforcement section with a separate second reinforcement section, the second reinforcement section being configured to include at least one cavity; c) substantially penetrating the at least one cavity of the separate second reinforcement section by the at least one projection upon the mating and wherein prior to expansion:
i. the at least one projection substantially extends into the at least one cavity of the separate second reinforcement section; andii. the at least one projection has substantially similar size as any other projection; d) aligning the at least one projection with an aperture defined in the second reinforcement section, so that when the first expandable polymeric material is subjected to a predetermined condition the material will expand and flow through the aperture, where it will remain upon curing of the material, thereby causing the first reinforcement section to be coupled with the second reinforcement section, wherein the method is free of a step of adding any separate local reinforcement components beyond that which exists from the first reinforcement section and the second reinforcement section; e) locating the first and second reinforcement sections into the vehicle cavity for providing structural reinforcement to the cavity.