Structural member reinforcement

A structural member reinforcement includes a body portion having a plurality of side walls. The side walls are spaced to define an opening therebetween. A plurality of cells are disposed in the opening between the side walls. Each of the plurality of cells defines a channel. An expandable material, such as structural foam or noise vibration and harshness (NVH) foam, is disposed in the channel of at least one of the plurality of cells. The reinforcement may be used to reinforce a structural member, such as a vehicle frame. The structural member may define a cavity, and the reinforcement may be disposed within the cavity.

BACKGROUND

1. Field of the Invention

The present disclosure relates to a reinforcement for a structural member.

2. Description of the Related Art

Reinforcing structural members is beneficial to many different industries when manufacturing products to have a minimum amount of structural integrity. Often times, weight is a consideration when making such reinforcements. To reduce weight, the structural member may be hollow, defining a cavity. A reinforcement may be placed in the cavity to strengthen the structural member, the idea being that the weight of the structural member with the reinforcement is lower than the weight of a solid structural member. This is especially true if the reinforcement is made from lighter materials than the structural member. For instance, the structural member may be formed from steel, whereas the reinforcement may be formed from a plastic.

Another consideration is the structural integrity of the hollowed structural member with the reinforcement disposed in the cavity. This is especially true if the reinforcement is formed from a lighter material than the structural member. Increasing the structural integrity of the reinforcement may include providing the reinforcement with an internal rib structure or coating an outer surface of the reinforcement with a structural foam. Although previous configurations of the internal rib structure and the structural foam on the outside of the reinforcement have met the standards for reinforcing the structural member, other configurations of the reinforcement may further increase the structural integrity of the reinforcement and the structural member. This may be beneficial to many industries, such as the automotive or aerospace industries, where a significant increase in structural integrity with a minimum increase in weight is ideal.

Accordingly, despite previous attempts to increase the structural integrity of the reinforcement and the structural member, a reinforcement is needed that improves upon the internal rib structure of the previous reinforcements by increasing the structural integrity of the reinforcement and the structural member without a significant increase in weight.

DETAILED DESCRIPTION

A reinforcement is provided that includes a body portion that has a plurality of side walls. The side walls define an opening, and a plurality of cells are disposed in the opening between the side walls. Each of the plurality of cells defines a channel, and an expandable material is disposed in the channel of at least one of the plurality of cells. Accordingly, the reinforcement may provide structural support and/or sound and vibration dampening in the cavity.

Referring to the Figures, wherein like numerals indicate like or corresponding parts throughout the several views, a reinforcement10is shown at numeral10.FIG. 1illustrates an exemplary reinforcement10disposed in a cavity12defined by a frame14. The reinforcement10includes a body portion16having a plurality of side walls18defining an opening therebetween. A plurality of cells20are disposed in the opening between the side wall18. Each of the plurality of cells20defines a channel22. In one embodiment, the channel22has an open-ended configuration. As discussed in greater detail below, the open-ended configuration may be further defined as a hexagonal configuration, a cylindrical configuration, a conical configuration, or a telescoping configuration. The various configurations may improve energy dissipation and provide additional structural integrity when forces act to compress the frame14and the reinforcement10. The plurality of cells20may be integrally formed with one another and/or integrally formed with the body portion16.

In one embodiment, the frame14is a vehicle frame14; however, it is to be appreciated that the frame14and the reinforcement10may be used in other applications. Vehicle frame may be formed from steel and the body portion16of the reinforcement10may be formed from nylon. The reinforcement10may be formed using various methods, including extrusion or injection molding. It is to be further understood that the frame14and reinforcement10may be formed from other materials.

The frame14defines an axis that extends through the cavity12. Depending on the application, the reinforcement10may be disposed in various orientations relative to the axis. For example, the reinforcement10may be disposed in the cavity12parallel to the axis. Specifically, the channel22defined by the plurality of cells20is parallel to the axis. In another embodiment, the reinforcement10may be disposed in the cavity12perpendicular to the axis. Specifically, the channel22defined by the plurality of cells20is perpendicular to the axis. The various orientations of the reinforcement10may aid in energy dissipation, reduce crushing of the frame14, or have other benefits.

Referring now toFIGS. 2-7, an expandable material24is disposed in the channel22of at least one of the plurality of cells20. Also, the expandable material24may be disposed on at least one of the plurality of side walls18. In one embodiment, the expandable material24that is disposed in the channel22of the cells20is the same type of expandable material24that is disposed on the side wall18. The expandable material24of the reinforcement10may be formed from an epoxy-based resin. For instance, the expandable material24may be structural foam or a noise vibration and harshness (NVH) foam. However, it is to be appreciated that the expandable material24may be any other material besides a structural foam or a NVH foam. In another embodiment, a first expandable material26is disposed in the channel22of at least one of the cells20and a second expandable material28is disposed on at least one of the side wall18. In one embodiment, the first expandable material26and the second expandable material28are different types of structural foams. In this embodiment, both the first expandable material26and the second expandable material28increase the structural integrity of the reinforcement10and the frame14. In another embodiment, the first expandable material26is the NVH foam and the second expandable material28is the structural foam. In this embodiment, the first expandable material26may be used to reduce noise and vibrations while the second expandable material28increases the structural integrity of the frame14. Regardless of the type used, expanding the expandable material24may include heating the expandable material24. For instance, in a vehicle assembly line, the vehicle is heated as it passes through a paint bake oven. The heat from the paint bake oven may be used to expand the expandable material24.

FIG. 2illustrates, in one embodiment, a perspective view of the reinforcement10having cells20with the hexagonal configuration. The expandable material24is disposed inside the channels22defined by the cells20, and specifically, the expandable material24coats at least one of the inner walls of the cells20. In another embodiment, referring now toFIG. 3, the expandable material24is disposed at a corner between two of the inner walls of the cells20. Regardless of the location, the expandable material24may be disposed in the channel22using various methods. For instance, the reinforcement10may be over molded to include the expandable material24. However, it is to be understood that the expandable material24may be disposed in the cells20via other methods. Referring now toFIG. 4, once expanded, the expandable material24fills the channel22defined by the cells20having the hexagonal configuration.

FIG. 5illustrates, in another embodiment, a perspective view of the reinforcement10having the cells20with the cylindrical configuration. Like in the previous embodiment, the expandable material24is disposed inside the channels22defined by the cells20, and specifically, the expandable material24is disposed on at least a portion of the inner wall of the cells20. The expandable material24may be disposed in the channel22using various methods. For instance, the reinforcement10may be over molded to include the expandable material24. However, it is to be understood that the expandable material24may be disposed in the cells20via other methods. Once expanded, the expandable material24fills the channel22defined by the cell20having the cylindrical configuration. In addition, the expandable material24may further be disposed on the body portion16of the reinforcement10having cells20with the cylindrical configuration. In one embodiment, a bottom portion30of each cell20may define a hole. As such, the expandable material24may include a plurality of pins32, each one extending through one of the holes. This may allow the expandable material24to remain disposed on the reinforcement10before the expandable material24is expanded.

FIG. 6illustrates, in yet another embodiment, a perspective view of the reinforcement10having the cells20with the conical configuration. Like in the previous embodiment, the expandable material24is disposed inside the channels22defined by the cells20, and specifically, the expandable material24is disposed on at least a portion of the inner wall of the cells20. The expandable material24may be disposed in the channel22using various methods. For instance, the reinforcement10may be over molded to include the expandable material24. However, it is to be understood that the expandable material24may be disposed in the cells20via other methods. Once expanded, the expandable material24fills the channel22defined by the cell20having the conical configuration. In addition, the expandable material24may further be disposed on the body portion16of the reinforcement10having cells20with the conical configuration. As in the previous embodiment the bottom portion30of each cell20may define the hole. As such, the expandable material24may include the plurality of pins32, each one extending through one of the holes. This may allow the expandable material24to remain disposed on the reinforcement10before the expandable material24is expanded.

FIG. 7illustrates, in yet another embodiment, a side view of the reinforcement10having the cells20with the telescoping configuration. Specifically, each cell20includes at least two segments34having different sizes, but similar shapes. As illustrated, each cell20has three segments34having a generally circular shape. However, it is to be appreciated that each cell20may have any number of segments34or generally any shape. Also, the segments34may be disposed in a telescoping configuration. Like in the previous embodiments, the expandable material24is disposed inside the channels22defined by the cells20, and specifically, the expandable material24is disposed on at least a portion of the inner wall of the cells20. The expandable material24may be disposed in the channel22using various methods. For instance, the reinforcement10may be over molded to include the expandable material24. However, it is to be understood that the expandable material24may be disposed in the cells20via other methods. Once expanded, the expandable material24fills the channel22defined by the cell20having the telescoping configuration. In addition, the expandable material24may further be disposed on the body portion16of the reinforcement10having cells20with the telescoping configuration. As in the previous embodiment, the bottom portion30of each cell20may define the hole. As such, the expandable material24may include the plurality of pins32, each one extending through one of the holes. This may allow the expandable material24to remain disposed on the reinforcement10before the expandable material24is expanded.