Reinforced structural assembly with acoustic foam member and method of reinforcing vehicle components

A method of manufacturing a structural assembly for a vehicle comprising:

• securing a flexible container at least partially filled with expandable foam to a first vehicle component;
• joining a second vehicle component to the first vehicle component such that the flexible container at least partially filled with expandable foam is within a cavity defined by the first and the second vehicle components;
• and
• causing the foam to expand such that the foam and the flexible container substantially fill the cavity and the flexible container contacts at least a portion of an inner surface of the joined vehicle components.

A method of manufacturing a structural assembly for a vehicle comprising:

• filling a flexible container at least partially with an expandable foam;
• wherein an outer surface of the flexible container has a sealant with adhesive properties;
• securing the flexible container at least partially filled with the expandable foam to a first vehicle component;
• welding a second vehicle component to a flange of the first vehicle component adjacent the flexible container such that the flexible container at least partially filled with the expandable foam is within a closed cavity defined by the welded first and the second vehicle components;
• and
• causing the foam to expand such that the foam and the flexible container substantially fill the cavity, the flexible container contacts at least a portion of an inner surface of the joined vehicle components, and the sealant with adhesive properties adheres the flexible container to said at least a portion of the inner surface of the joined vehicle components and seals the expanded foam.

A method of manufacturing a structural assembly for a vehicle comprising:

• measuring a predetermined quantity of expandable foam;
• filling a flexible container at least partially with the predetermined quantity of expandable foam;
• wherein an outer surface of the flexible container has a sealant with adhesive properties;
• wherein said filling is through an opening in the flexible container;
• sewing shut the opening of the flexible container;
• after said sewing shut, securing the flexible container at least partially filled with the expandable foam to a first vehicle component;
• wherein said securing includes threading a fastener to the first vehicle component;
• welding a second vehicle component to a flange of the first vehicle component adjacent the flexible container such that the flexible container at least partially filled with the expandable foam is within a closed cavity defined by the welded first and second vehicle components;
• and
• causing the foam to expand such that the foam and the flexible container substantially fill the cavity, the flexible container contacts at least a portion of an inner surface of the joined vehicle components, and the sealant with adhesive properties adheres the flexible container to said at least a portion of the inner surface of the joined vehicle components and seals the expanded foam.