# US 2019/0168808 A1 · Multiple stage deformation reinforcement structure for impact absorption > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2019/0168808 A1 - Document ID: US20190168808A1 - Status: Published application - Kind: A1 - Application number: 16/251,206 - Filed: 2019-01-18 - Published: 2019-06-06 - Earliest claimed: 2016-07-28 - Assignees: Zephyros, Inc. - Applicants: Zephyros, Inc. - Inventors: Liwen Li; Henry E. Richardson - Web page: https://patentgrep.com/patent/US20190168808A1 ## CPC - B62D 21/15: having impact absorbing means, e.g. a frame designed to permanently or temporarily change shape or dimension upon impact with another body (bumpers B60R19/02; shock absorbers in general F16F) - B62D 21/157: {for side impacts} - B62D 25/00: Superstructure {or monocoque structure} sub-units; Parts or details thereof not otherwise provided for {(having impact absorbing means B62D21/15; running-boards, steps, or the like as superstructure sub-unit B60R3/00)} - B62D 29/002: {a foamable synthetic material or metal being added in situ (shaping of substances in a plastic state by foaming, in general B29C44/00)} - B62D 29/04: predominantly of synthetic material (working of plastics or substances in a plastic state B29) - B62D 25/025: {Side sills thereof} - B62D 25/04: Door pillars {; windshield pillars} - B62D: MOTOR VEHICLES; TRAILERS (steering, or guiding on a desired track, of agricultural machines or implements A01B69/00; wheels, castors, axles, increasing wheel adhesion B60B; vehicle tyres, tyre inflation or tyre changing B60C; connections between vehicles of a train or the like B60D; vehicles for use on rail and road, amphibious or convertible vehicles B60F; suspension arrangements B60G; heating, cooling, ventilating or other air treating devices B60H; windows, windscreens, non-fixed roofs, doors or similar devices, protective coverings for vehicles not in use B60J; propulsion plant arrangements, auxiliary drives, transmissions, controls, instrumentation or dashboards B60K; electric equipment or propulsion of electrically-propelled vehicles B60L; power supply for electrically-propelled vehicles B60M; passenger accommodation not otherwise provided for B60N; adaptations for load transportation or to carry special loads or objects B60P; arrangement of signalling or lighting devices, the mounting or supporting thereof or circuits therefor, for vehicles in general B60Q; vehicles, vehicle fittings or vehicle parts not otherwise provided for B60R; servicing, cleaning, repairing, supporting, lifting, or manoeuvring, not otherwise provided for, B60S; brake arrangements, brake control systems or parts thereof B60T; air-cushion vehicles B60V; motor-cycles, accessories therefor B62J, B62K; testing of vehicles G01M) ## 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. ## Claims ### Claim 1 A structural reinforcement for a vehicle comprising: a) a carrier having: i) a base wall, ii) a first portion having a plurality of first projections which form one or more first cell-like structures extending from the base wall, iii) a second portion having a plurality of second projections which form one or more second cell-like structures extending from the base wall, b) an activated material affixed to the carrier and located on the first portion, wherein the activatable material is configured to secure the carrier in a cavity of the vehicle; wherein the plurality of first projections and the plurality of second projections include one or more ribs; wherein in event of an impact, the plurality of first projections and the plurality of second projections are configured to deform toward the base wall, in a direction of an impact load, or both in response to the impact load; and wherein the plurality of first projections is configured to receive the impact load and deform before the plurality of second projections receives the impact load and deforms. ### Claim at position 2 2-19. (canceled) ### Claim 20 (depends on 1) A method for making the structural reinforcement according to claim 1 comprising: a) performing finite element analysis to simulate the impact load; b) generating a design of the carrier that has a structure according to claim 1 based upon results of the finite element analysis; c) injection molding the carrier according to the design; and d) locating the activatable material onto an external surface of the carrier. ### Claim 21 (depends on 1) The structural reinforcement of claim 1, wherein the plurality of first projections has a height greater than a height of the plurality of second projections. ### Claim 22 (depends on 1) The structural reinforcement of claim 1, wherein the carrier includes one or more openings between any of the plurality of first projections, the plurality of second projections, or both. ### Claim 23 (depends on 1) The structural reinforcement of claim 1, wherein at least some of the plurality of first projections extend in a same direction, opposite direction, or both from the base wall as the plurality of second projections. ### Claim 24 (depends on 1) The structural reinforcement of claim 1, wherein the plurality of first projections and the plurality of second projections are all rib structures. ### Claim 25 (depends on 1) The structural reinforcement of claim 1, wherein the activatable material expands upon activation. ### Claim 26 (depends on 25) The structural reinforcement of claim 25, wherein the activatable material expands to about 200% or greater of an original volume to about 2500% or less of the original volume. ### Claim 27 (depends on 25) The structural reinforcement of claim 25, wherein the activatable material surrounds at least a portion of the second portion of the carrier. ### Claim 28 (depends on 25) The structural reinforcement of claim 25, wherein the carrier is reinforced by glass fibers. ### Claim 29 (depends on 1) The structural reinforcement of claim 1, wherein the plurality of first projections, the plurality of second projections, or both include at least one pair of intersecting projections. ### Claim 30 (depends on 29) The structural reinforcement of claim 29, wherein the one or more first cell-like structures, the one or more second cell-like structures, or both are open cell-like structures, closed cell-like structures, or both. ### Claim 31 (depends on 25) The structural reinforcement of claim 25, wherein the activatable material is a structural foam, an acoustical foam, a sealant, or any combination thereof. ### Claim 32 (depends on 31) The structural reinforcement of claim 31, wherein the activatable material is an epoxy-based material. ### Claim 33 A structural reinforcement for a vehicle comprising: a) a carrier having: i) a base wall, ii) a first portion having a plurality of first projections which form one or more first cell-like structures extending from the base wall, iii) a second portion having a plurality of second projections which form one or more second cell-like structures extending from the base wall, b) an activatable material affixed to the carrier and located on the first portion, wherein the activatable material is configured to secure the carrier in a cavity of the vehicle; wherein the plurality of first projections and the plurality of second projections are rib structures; wherein in event of an impact, the plurality of first projections and the plurality of second projections are configured to deform toward the base wall, in a direction of an impact load, or both in response to the impact load; and wherein the plurality of first projections is configured to receive the impact load and deform before the plurality of second projections receives the impact load and deforms. ### Claim 34 (depends on 33) The structural reinforcement of claim 33, wherein at least some of the plurality of first projections extend in a same direction, opposite direction, or both from the base wall as the plurality of second projections. ### Claim 35 (depends on 34) The structural reinforcement of claim 34, wherein the plurality of first projections, the plurality of second projections, or both include at least one pair of intersecting projections. ### Claim 36 (depends on 35) The structural reinforcement of claim 35, wherein the plurality of first projections has a height greater than a height of the plurality of second projections. ### Claim 37 (depends on 36) The structural reinforcement of claim 36, wherein the activatable material expands upon activation; and wherein the activatable material is an epoxy-based material. ### Claim 38 (depends on 37) The structural reinforcement of claim 37, wherein the carrier is a molded polymeric carrier which is reinforced by glass fibers.