Structural reinforcement member and method of use therefor

A structural reinforcement member, comprising:

• a carrier member having a first wall and a second wall and a length extending along an axis, the carrier member including:
• i. a plurality of substantially planar ribs cooperatively forming a plurality of cavities aligned along the length of the carrier member, the plurality of ribs extending substantially perpendicular to the axis of the carrier member;
• and
• ii. a concavity defined by the first wall and the second wall wherein the plurality of ribs are located substantially entirely within the concavity, wherein at least one of the plurality of ribs includes an indentation that corresponds at least partially to the shape of the concavity:
• a plurality of masses of expandable material respectively disposed within the plurality of cavities between the plurality of ribs, wherein:
• i. the plurality of masses of expandable material expand upon exposure to an elevated temperature to form a plurality of masses of reinforcing foam, which having a compression strength of at least about 13 MPa.

A structural reinforcement member, comprising:

• a carrier member having a length extending along an axis, the carrier member including:
• i. a first substantially planar wall having an external outwardly facing surface, the first wall being substantially planar in a first plane;
• ii. a second substantially planar wall having an external outwardly facing surface, the second wall being substantially planar in a second plane, the first wall adjoining the second wall, the second plane being skew to the first plane;
• iii. three sets of substantially planar ribs extending between and adjoining the first wall and the second wall and cooperatively forming a plurality of cavities aligned along the length of the carrier member, the plurality of ribs being substantially planar in planes extending substantially perpendicular to the axis of the carrier member, wherein a first set of the substantially planar ribs includes only ribs that are perpendicular to the first wall and a second set and a third set of the substantially planar ribs include ribs that are perpendicular to the first wall and ribs that are parallel to the first wall;
• iv. a concavity defined by the first wall and the second wall wherein the three sets of ribs are located substantially entirely within the concavity, wherein each of the first set of ribs includes an indentation that corresponds at least partially to the shape shape of the concavity;
• and
• v. at least one through-hole so that material can move from the exterior of the first wall or second wall into the concavity;
• a plurality of masses of expandable material respectively disposed within the plurality of cavities between the plurality of ribs, wherein:
• i. the cavities each have a volume and the plurality of masses of expandable material respectively occupy no more than 70% of the volume of each of the cavities;
• ii. the plurality of masses of expandable material expand upon exposure to an elevated temperature to form a plurality of masses of reinforcing foam, which having a compression strength of at least about 13 MPa and which occupy greater than 80% of the volume of each of the cavities;
• and
• iii. the expandable material being located onto the first or second wall can at least partially be fed through the at least one through-hole into the cavities.