Structural reinforcements

A reinforcement system for a structural member, the system comprising:

• a polymeric carrier having a length extending between a first end and a second end, the carrier forming at least three cavities arranged along the carrier wherein each of the three cavities includes at least one through-hole and a plurality of integrally formed walls;
• an activatable material comprising an epoxy-based structural foam placed over at least a portion of the exterior of the carrier, the activatable material being configured to expand upon application of heat and adhere to the carrier and adhere to a wall of a cavity in which the carrier is located;
• a plurality of intermediate restrictors integrally formed with the carrier, the intermediate restrictors being formed as one or more openings formed as grooves along an outer portion of the carrier whereby:
• i. at least a portion of the activatable material is plastically deformed to enter into each of the grooves prior to expansion;
• ii. the grooves prevent horizontal movement of the activatable material with respect to the carrier by acting as a stop and the grooves allow vertical movement upon expansion of the activatable material;
• iii. the activatable material maintains contact with the carrier prior to expansion;
• iv. the carrier is free of any separate fasteners for maintaining the location of the activatable material;
• v. the location of the grooves along the outer portion of the carrier allows at least a portion of the activatable material to exit the groove during expansion of the activatable material;
• and
• vi. the grooves are located along at least two walls of each integrally formed cavities;
• vii. the grooves are formed within the carrier to form a unitary structure and include openings having a consistent shape so that a consistent amount of the activatable material enters each opening to limit movement of the activatable material in a direction perpendicular to a longitudinal axis of the carrier.