Patent ID: 6863957
Filing Date: 2005-03-08
Classification: B29C,B29L,B62D,Y10T

Abstract:
1. A reinforced structural assembly comprising a structural member having at least one wall, a reinforcing member disposed adjacent to said wall, said reinforcing member having a carrier portion and an expanded portion, said carrier portion supporting said expanded portion, said expanded portion being bonded to said wall of said structural member and being bonded to said carrier portion, said expanded portion in its unexpanded form being a one-part epoxy system having an outer surface disposed toward said wall of said structural member, said epoxy system containing in weight percent about 30% to about 70% epoxy resin and containing a filler in the form of hollow glass microspheres, said epoxy system being in the form of a high-viscosity dough so that said epoxy dough in its uncured state does not significantly flow from and remains supported by said carrier portion without the need for additional restraining structure at said outer surface to form a unit with said carrier portion whereby said unit may be placed near said wall before said epoxy dough is cured to bond said unit to said wall when said, epoxy dough is cured and expands into intimate contact with said wall, said epoxy dough being resistant to acid and bases in its uncured state, said epoxy dough having a compressive strength after expanding and curing of at least 1000 psi, and said epoxy dough having a density of about 35 pcf to about 65 pcf before being fully cured and from about 25 pcf to about 45 pcf after being fully expanded.