# US 8,771,564 B2 · Shaped expandable material > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,771,564 B2 - Document ID: US8771564B2 - Status: Granted - Kind: B2 - Application number: 13/917,061 - Filed: 2013-06-13 - Published: 2013-10-17 - Granted: 2014-07-08 - Earliest claimed: 2005-10-25 - Assignees: Zephyros, Inc. - Applicants: Zephyros, Inc. - Inventors: Abraham Kassa; David Kosal; Kevin Hicks - Web page: https://patentgrep.com/patent/US8771564B2 ## CPC - B29C 44/128: {Internally reinforcing constructional elements, e.g. beams} - B29C 44/18: Filling preformed cavities {(B29C44/1204 takes precedence)} - B29C 44/186: {Filling multiple cavities (B29C44/181, B29C44/182 and B29C44/188 takes precedence)} - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) ## Abstract An expandable material is shaped to form a part that can provide functional attributes such as reinforcement to a structure of article of manufacture such as an automotive vehicle. ## Claims ### Claim 1 A method of reinforcing a structure of an article of manufacture, the method comprising: providing an expandable material having a self supporting characteristic during expansion thereof that is due to partial curing of the expandable material, fast cure time of the expandable material or the inclusion of one or more of the following in the expandable material: i) relatively high molecular weight polymeric material; ii) toughened thermoplastic; or iii) thixotropic or fibrous filler; shaping the expandable material into a part; inserting the part into a cavity that is at least partially defined by a structure of the article of manufacture; and activating the activatable material to cure, expand and adhere to walls of the structure. ### Claim 2 (depends on 1) A method as in claim 1 wherein the expandable material is substantially tack-free to the touch. ### Claim 3 (depends on 1) A method as in claim 1 wherein the part, upon activation, forms a foam that exhibits a compressive strength greater than about 5 Mpa. ### Claim 4 (depends on 1) A method as in claim 1 wherein the part is skeletal. ### Claim 5 (depends on 1) A method as in claim 1 wherein the article of manufacture is an automotive vehicle. ### Claim 6 (depends on 1) A method as in claim 1 wherein the shaping of the expandable material includes molding or extruding the material to have a shape that at least partially corresponds to the cavity. ### Claim 7 (depends on 1) A method as in claim 1 wherein the parts are substantially without supports and molded carriers upon insertion into the cavity. ### Claim 8 (depends on 1) A method as in claim 1 wherein the expandable material is at least 90% by weight of the part upon insertion of the part into the cavity. ### Claim 9 (depends on 1) A method as in claim 1 wherein the part shaped of expandable material is a tubular structure with internal ribs, both the tubular structure and the ribs being formed of the expandable material. ### Claim 10 A method of reinforcing a structure of an automotive vehicle, the method comprising: providing an expandable material having a self supporting characteristic during expansion thereof that is due to partial curing of the expandable material or fast cure time of the expandable material and the inclusion of two or more of the following in the expandable material: i) relatively high molecular weight polymeric material including epoxy resin having a molecular weight greater than about 1200; ii) toughened thermoplastic including toughened TPER; or iii) fibrous filler; shaping the expandable material into a part; inserting the part into a cavity that is at least partially defined by a structure of the automotive vehicle; and activating the activatable material to cure, expand and adhere to walls of the structure wherein the part substantially maintains is shape during expansion. ### Claim 11 (depends on 10) A method as in claim 10 wherein the expandable material is substantially tack-free to the touch. ### Claim 12 (depends on 11) A method as in claim 11 wherein the part, upon activation, forms a foam that exhibits a compressive strength greater than about 5 Mpa. ### Claim 13 (depends on 12) A method as in claim 12 wherein the part is skeletal. ### Claim 14 (depends on 12) A method as in claim 12 wherein the shaping of the expandable material includes molding or extruding the material to have a shape that at least partially corresponds to the cavity. ### Claim 15 (depends on 12) A method as in claim 12 wherein the parts are substantially without supports and molded carriers upon insertion into the cavity. ### Claim 16 (depends on 10) A method as in claim 10 wherein the expandable material is at least 90% by weight of the part upon insertion of the part into the cavity. ### Claim 17 (depends on 10) A method as in claim 10 wherein the part shaped of expandable material is a tubular structure with internal ribs, both the tubular structure and the ribs being formed of the expandable material. ### Claim 18 A method of reinforcing a structure of an automotive vehicle, the method comprising: providing an expandable material having a self supporting characteristic during expansion thereof that is due to partial curing of the expandable material or fast cure time of the expandable material and the inclusion of two or more of the following in the expandable material: i) relatively high molecular weight polymeric material including epoxy resin having a molecular weight greater than about 1200; ii) toughened thermoplastic including toughened TPER; or iii) aramid fiber; shaping the expandable material into a part wherein shaping of the part includes extrusion of the part to having a tubular shape with internal ribs; inserting the part into a cavity that is at least partially defined by a structure of the automotive vehicle; and activating the activatable material to cure, expand and adhere to walls of the structure. ### Claim 19 (depends on 18) A method as in claim 18 wherein: i. the expandable material is substantially tack-free to the touch; ii. the part, upon activation, forms a foam that exhibits a compressive strength greater than about 5 Mpa; and iii. wherein the shaping of the expandable material includes molding or extruding the material to have a shape that at least partially corresponds to the cavity. ### Claim 20 (depends on 19) A method as in claim 19 wherein: i. the parts are substantially without supports and molded carriers upon insertion into the cavity; and ii. the expandable material is at least 95% by weight of the part upon insertion of the part into the cavity.