Patent ID: 8127506

Claim:
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 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 forming 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 and 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.