# US 11,110,670 B2 · Structural reinforcements

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- Number: US 11,110,670 B2
- Document ID: US11110670B2
- Status: Granted
- Kind: B2
- Application number: 16/084,089
- Filed: 2017-03-15
- Published: 2019-03-14
- Granted: 2021-09-07
- Earliest claimed: 2016-03-15
- Assignees: Zephyros, Inc.
- Applicants: Zephyros, Inc.
- Inventors: Henry Richardson; Nick Holstine
- Web page: https://patentgrep.com/patent/US11110670B2

## CPC

- B29C 70/52: Pultrusion, i.e. forming and compressing by continuously pulling through a die
- B29C 70/68: by incorporating or moulding on preformed parts, e.g. inserts or layers {, e.g. foam blocks (mould constructions therefor B29C33/12; joining preformed parts by moulding B29C65/70)}
- B29C 70/887: {locally reinforced, e.g. by fillers (filler concentrated near the surface B29C70/64)}
- B32B 5/022: {Non-woven fabric}
- B32B 5/024: {Woven fabric}
- B32B 5/18: characterised by features of a layer {of} foamed material
- B32B 5/20: foamed in situ
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 19/00: Layered products comprising {a layer of} natural mineral fibres or particles, e.g. asbestos, mica
- B32B 27/065: {of foam}
- B32B 27/08: of synthetic resin
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/286: {comprising polysulphones; polysulfides}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 27/34: comprising polyamides
- B32B 27/36: comprising polyesters
- B32B 27/365: {comprising polycarbonates}
- B32B 27/40: comprising polyurethanes
- C08J 5/04: Reinforcing macromolecular compounds with loose or coherent fibrous material
- C08J 5/244: {using glass fibres}
- B32B 2260/021: Fibrous or filamentary layer
- B32B 2260/046: Synthetic resin
- B32B 2262/02: Synthetic macromolecular fibres
- B32B 2262/065: Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
- B32B 2262/101: Glass fibres
- B32B 2262/103: Metal fibres
- B32B 2262/106: Carbon fibres, e.g. graphite fibres
- B32B 2262/14: Mixture of at least two fibres made of different materials
- B32B 2307/102: Insulating
- B32B 2307/54: Yield strength; Tensile strength
- B32B 2307/542: Shear strength
- B32B 2307/546: Flexural strength; Flexion stiffness
- B32B 2307/732: Dimensional properties
- B32B 2419/00: Buildings or parts thereof
- B32B 2509/00: Household appliances
- B32B 2605/08: Cars
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)

## Abstract

A structural reinforcement for an article including a carrier (10) that includes: (i) a mass of polymeric material (12) having an outer surface; and (ii) at least one fibrous composite insert (14) or overlay (960) having an outer surface and including at least one elongated fiber arrangement (e.g., having a plurality of ordered fibers). The fibrous insert (14) or overlay (960) is envisioned to adjoin the mass of the polymeric material in a predetermined location for carrying a predetermined load that is subjected upon the predetermined location (thereby effectively providing localized reinforcement to that predetermined location). The fibrous insert (14) or overlay (960) and the mass of polymeric material (12) are of compatible materials, structures or both, for allowing the fibrous insert or overlay to be at least partially joined to the mass of the polymeric material. Disposed upon at least a portion of the carrier (10) may be a mass of activatable material (126). The fibrous insert (14) or overlay (960) may include a polymeric matrix.

## Claims

### Claim 1

A device comprising:
(a) an elongated pultruded carrier, the carrier including:
i) a fiber phase and a polyurethane matrix phase, the fiber phase being surrounded in its entirety by the matrix phase; and
ii) a longitudinal axis whereby the carrier is shaped symmetrically on opposing sides of the longitudinal axis;
(b) an expandable sealant material located in direct planar contact with a portion of the carrier, the expandable sealant material being located onto the carrier in a continuous manner via a pultrusion or extrusion process; and
(c) one or more film layer portions located in direct planar contact with the carrier, the one or more film layer portions being located onto the carrier in a continuous manner via a pultrusion or extrusion process, wherein the one or more film layer portions are disposed on the carrier about one or more fastener openings of the carrier and the one or more film layer portions are substantially free of contact with the expandable sealant material prior to any activation of the expandable sealant material;
wherein the carrier is formed to include a rib structure extending along the longitudinal axis of the carrier, and the rib structure is free of contact with the expandable sealant material and the one or more film layer portions;
wherein the carrier includes an outer surface and an opposing inner surface, and the rib structure projects from the inner surface; and
wherein the expandable sealant material is located on both the outer surface and the opposing inner surface of the carrier.

### Claim 2 (depends on 1)

The device of claim 1, wherein the one or more film layer portions comprise a polyethylene material.

### Claim 3 (depends on 1)

The device of claim 1, wherein the device is formed of at least four distinct material layers.

### Claim 4 (depends on 3)

The device of claim 3, wherein the at least four distinct material layers include a fiber layer, a matrix layer, a film layer and an expandable material layer.

### Claim 5 (depends on 4)

The device of claim 4, wherein the fiber layer comprises glass fibers, the film layer comprises polyethylene, and the expandable material layer comprises an epoxy material.

### Claim 6 (depends on 1)

The device of claim 1, wherein the device is cut into multiple pieces after formation.

### Claim 7 (depends on 1)

The device of claim 1, wherein the fiber phase comprises glass fibers arranged generally parallel to each other and having an average diameter of about 5 to about 25 microns, wherein each fiber has a length of at least 5 cm.

### Claim 8 (depends on 1)

The device of claim 1, wherein the device has a substantially constant profile along the longitudinal axis.

### Claim 9 (depends on 1)

The device of claim 1, wherein the carrier is formed to include at least two rib structures, and the at least two rib structures are free of contact with both the expandable sealant material and the one or more film layer portions.

### Claim 10 (depends on 9)

The device of claim 9, wherein the at least two rib structures are off-centered from the longitudinal axis and extend substantially parallel to the longitudinal axis.

### Claim 11 (depends on 1)

The device of claim 1, wherein the fiber phase comprises glass fibers.

### Claim 12 (depends on 11)

The device of claim 11, wherein the one or more film layer portions comprise a polyethylene material.

### Claim 13 (depends on 11)

The device of claim 11, wherein the device is formed of at least four distinct material layers.

### Claim 14 (depends on 13)

The device of claim 13, wherein the at least four distinct material layers include a fiber layer, a matrix layer, a film layer and an expandable material layer.

### Claim 15 (depends on 14)

The device of claim 14, wherein the device is cut into multiple pieces after formation.

### Claim 16 (depends on 14)

The device of claim 14, wherein the device has a substantially constant profile along the longitudinal axis.

### Claim 17 (depends on 11)

The device of claim 11, wherein the device has a substantially constant profile along the longitudinal axis.