Patent ID: 7094299

Claim:
A method for reinforcing hollow support structures comprising: providing the hollow support structure having an inner wall and a fill hole; introducing a pair of baffles within the hollow support structure; applying an electrocoat coating to said hollow support structure and said pair of baffles; heating said hollow support structure within an oven to expand said pair of baffles to seal to said inner wall of said hollow support structure, therein forming a cavity defined between each of said pair of baffles and within said inner wall; forming a two-component viscous fluid within a robotic viscous fluid application device; injecting a high volume of said two-component viscous fluid from said robotic viscous fluid application device through said fill hole at a high fill rate, wherein said two-component viscous fluid reacts to form a reacted viscous fluid and wherein said reacted viscous fluid expands to form a foam that substantially fills said cavity.