Structural mounting insert having a non-conductive isolator

An insert for adhesion, sealing, and isolating comprising:

• a generally non-conductive isolator defining a plurality of openings therethrough by a network of elongated strands that are constrained relative to each other against lateral displacement, the elongated strands being formed of a polyamide, a polyester, glass fibers, or any combination thereof;
• a matrix material embedded over the isolator and having a first tackiness in its green state, the matrix material being cured by exposure to heat after installation of the insert, wherein the first tackiness is sufficiently high so that it resists displacement after application to a surface;
• an outer surface having a second tackiness that is less than the first tackiness;
• wherein the isolator includes a thickness that ranges from about 0.1 mm to about 0.8 mm;
• wherein upon installation in a joint between two opposing members having dissimilar materials, the isolator resists any displacement that would bring the two dissimilar materials into direct contact with each other;
• wherein upon application of heat, the matrix material expands to fill the plurality of openings formed through the elongated strands and to seal and bond the isolator and a connection region between the dissimilar materials.

A mounting assembly between a shock tower housing and frame members of an automotive vehicle, the shock tower housing comprising:

• an outer wall extending generally transversely from a first housing portion to form a cavity therebetween, the first housing portion having an opening extending therethrough for accessing a portion of a shock absorber located within the cavity;
• a first mounting portion for attachment to a first vehicle frame member at a connection region, the first mounting portion having a mounting surface for mounting the first mounting portion to the first vehicle frame member;
• a second mounting portion for attachment to a second vehicle frame member at a connection region, the second mounting portion having a mounting surface for mounting the second mounting portion to the second vehicle frame member;
• a structural mounting insert comprising:
• a non-conductive structural mesh material shaped to correspond to the shape of the connection region, the non-conductive structural mesh material forming a plurality of equally shaped and spaced openings therethrough;
• and
• a heat activatable material encased over at least a portion of the non-conductive structural mesh material and in the plurality of openings formed therethrough, the heat activatable material being formed of a pliable material;
• and
• wherein the structural mounting inserts include a first and second structural mounting insert, the first structural insert further having one or more apertures passing through the first structural mounting insert, the one or more apertures having edges that are at least partially brought together upon being applied to the mounting surface of the first mounting portion so that the shape of the first structural mounting insert corresponds to a non-planar surface of the first mounting surface thereby reducing or eliminating any gaps formed between the non-planar surface and the first structural mounting insert, bunching of the first structural insert, or both relative to a similar structural mounting insert without the one or more apertures being applied to the non-planar surface;
• and
• a plurality of fasteners extending through the frame members and the inserts to the shock tower housing;
• wherein a material of the first mounting portion and second mounting portion are dissimilar to a material of the first frame member and second frame member and upon mounting the first and second mounting portions to the first and second vehicle frame members, the non-conductive structural mesh material resists any displacement that would bring the two dissimilar materials into direct contact with each other;
• wherein upon application of heat, the heat activatable material expands to fill the plurality of openings formed through the structural mesh and to seal and bond the structural mesh material and the connection region of the first mounting portion and the first vehicle frame member and the connection region of the second mounting portion and the second vehicle frame from a surrounding environment, and
• wherein upon application of heat, the heat activatable material expands to fill a surrounding area where the plurality of fasteners extend through the structural mounting inserts to substantially limit or prevent moisture from entering therein.

A mounting assembly between a shock tower housing and frame members of an automotive vehicle, the shock tower housing comprising:

• an outer wall extending generally transversely from a first housing portion to form a cavity therebetween, the first housing portion having an opening extending therethrough for accessing a portion of a shock absorber located within the cavity;
• a first mounting portion for attachment to a first vehicle frame member at a connection region, the first mounting portion having a mounting surface for mounting the first mounting portion to the first vehicle frame member;
• a second mounting portion for attachment to a second vehicle frame member at a connection region, the second mounting portion having a mounting surface for mounting the second mounting portion to the second vehicle frame member;
• structural mounting inserts comprising:
• a heat activatable material,
• wherein the structural mounting inserts include a first and second structural mounting insert, the first structural insert further having one or more apertures passing through the first structural mounting insert, the one or more apertures having edges that are at least partially brought together upon being applied to the mounting surface of the first mounting portion so that the shape of the first structural mounting insert corresponds to a non-planar surface of the first mounting surface thereby reducing or eliminating any gaps formed between the non-planar surface and the first structural mounting insert;
• and
• a plurality of fasteners extending through the frame members and the inserts to the shock tower housing;
• wherein a material of the first and second mounting portions is dissimilar to a material of the first and second vehicle frame members and upon mounting the first and second mounting portions to the first and second vehicle frame members, the structural mounting inserts resist any displacement that would bring the two dissimilar materials into direct contact with each other;
• wherein upon application of heat, the heat activatable material expands to seal and bond the connection region of the first mounting portion and the first vehicle frame member and the connection region of the second mounting portion and the second vehicle frame from a surrounding environment, and
• wherein upon application of heat, the heat activatable material expands to fill a surrounding area where the plurality of fasteners extend through the structural mounting inserts to substantially limit or prevent moisture from entering therein.