Three dimensional composite joint reinforcement for an automotive vehicle

A joint reinforcement member for hollow structure of an automotive vehicle comprising:

• a carrier portion having an outer surface, said carrier portion having a base portion having a first extension having a first longitudinal axis extending therefrom and having a second extension having a second longitudinal axis extending therefrom;
• a thermally expandable adhesive layer disposed on said outer surface and substantially covering said outer surface;
• and
• wherein said carrier portion has metal extensions extending therefrom.

A joint reinforcement member for hollow structure of an automotive vehicle comprising:

• a carrier portion having an outer surface, said carrier portion having a base portion having a first extension having a first longitudinal axis extending therefrom and having a second extension having a second longitudinal axis extending therefrom;
• a thermally expandable adhesive layer disposed on said outer surface and substantially covering said outer surface;
• and
• wherein said carrier portion comprises two stamped metal channels coupled together.

A joint reinforcement member for hollow structure of an automotive vehicle comprising:

• a carrier portion having an outer surface, said carrier portion having a base portion having a first extension having a first longitudinal axis extending therefrom and having a second extension having a second longitudinal axis extending therefrom;
• a thermally expandable adhesive layer disposed on said outer surface and substantially covering said outer surface;
• and
• wherein said carrier portion comprises a foil coated foam member, said foil forming said outer surface.

A joint reinforcement member for hollow structure of an automotive vehicle comprising:

• a carrier portion having an outer surface, said carrier portion having a base portion having a first extension having a first longitudinal axis extending therefrom and having a second extension having a second longitudinal axis extending therefrom;
• a thermally expandable adhesive layer disposed on said outer surface and substantially covering said outer surface;
• and
• wherein said adhesive layer comprises by percentage weight,
• synthetic resin between about 40% and about 80%
• filler between about 1% and about 15%
• chemical blowing agent between about 0.5% and about 5%.

A method of forming a reinforcement member for placement within a hollow structure member of an automotive vehicle comprising:

• providing a carrier portion having a plurality of extensions extending from a base portion corresponding to the hollow structure;
• applying a layer of thermally expandable adhesive material to said carrier portion;
• heating the carrier portion and the adhesive layer;
• activating the adhesive layer;
• bonding the adhesive layer to a structural member;
• and
• cooling the structural member and the adhesive layer;
• and further comprising the step of cutting the adhesive layer from a sheet of adhesive material.

A method forming a reinforcement member for placement within a hollow structure member of an automotive vehicle comprising:

• providing a carrier portion having a plurality of extensions extending from a base portion corresponding to the hollow structure;
• applying a layer of thermally expandable adhesive material to said carrier portion;
• heating the carrier portion and the adhesive layer;
• activating the adhesive layer;
• bonding the adhesive layer to a structural member;
• and
• cooling the structural member and the adhesive layer;
• wherein the step of applying the layer of adhesive material further comprises the sub-steps of placing the carrier portion in a mold;
• injecting the adhesive layer between the carrier portion and the mold;
• and, removing the carrier portion having the adhesive layer from the mold.

A method of forming an automotive body having at least two elongated hollow body members, the assembly of said body members defining a hollow space therebetween comprising:

• inserting a reinforcement member in the hollow space, the reinforcement member having a carrier portion having an outer surface and a base portion having a first extension having a first longitudinal axis extending therefrom and having a second extension having a second longitudinal axis extending therefrom, the outer surface of the carrier having a thermally expandable adhesive layer disposed thereon;
• aligning the first extension with the one of the hollow body members;
• aligning the second extension with the other of the hollow body members;
• heating the body members, the carrier portion and the adhesive layer;
• bonding the adhesive material within the hollow body members;
• and
• cooling the structural member and the adhesive layer;
• and further comprising the steps of forming the adhesive layer by cutting the adhesive layer from a sheet of adhesive material.