Reinforcement structure and method employing bulkheads

A method for manufacturing a structural reinforcement device for insertion into a cavity of a structure, comprising the steps of:

• a) providing a generally planar first reinforcement section including opposing edge portions and having a first side and a generally opposing second side that has at least one projection of a first thermally expandable polymeric material secured to it;
• b) mating the first reinforcement section with a separate elongated second reinforcement section, the second reinforcement section being configured to include at least one cavity and at least two inwardly projecting flaps such that the volume between the at least two flaps receives the at least one projection during the mating step, wherein the second reinforcement section includes opposing spaced apart surfaces that are aligned with the opposing edge portions of the first reinforcement section;
• c) providing a second thermally expandable material, wherein the second thermally expandable material has the same or a different composition than the first thermally expandable material;
• and
• d) aligning the at least one projection with an aperture defined in the second elongated reinforcement section, so that when the first and second thermally expandable polymeric materials are subjected to a predetermined condition the materials will expand and one or more of the materials will flow through the aperture, where it will remain upon curing of the materials, the first and second thermally expandable polymeric materials 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.