Flexible structural reinforcement
The present teachings generally relate to a flexible, structural carrier for reinforcement of hollow tubes, cavities, and the like. The structural carrier comprises two or more reinforcing member segments; a foamable material disposed along a portion of the two or more reinforcing member segments; and at least one insert that connects the two or more reinforcing member segments in a manner that enables flexible movement of the segments relative to each other. The carrier is adapted for the structural reinforcement of a hollow tube or cavity featuring complex curvatures.
1 . A structural carrier comprising:
i. two or more reinforcing member segments;
ii. a foamable material disposed along a portion of the two or more reinforcing member segments; and
iii. at least one insert that connects the two or more reinforcing member segments, the at least one insert comprising a first material that is overmolded or insert molded with a second material, the second material being different from the first material, and the first material does not adhere to the second material so that the first material can move freely relative to the second material;
wherein the structural carrier is adapted for the structural reinforcement of a hollow tube or cavity.
2 . The structural carrier of claim 1 , wherein the two or more reinforcing member segments include one or more ribs for substantially preventing the structural carrier from excessive rotation.
3 . The structural carrier of claim 1 , wherein the foamable material is an adhesive, sealant, or combination thereof.
4 . The structural carrier of claim 3 , wherein the at least one insert may be a swivel, a ball and socket, concentric circles, football shaped, H-shaped, or any combination thereof.
5 . The structural carrier of claim 4 , wherein the first material is a polymeric material that is different from the second material.
6 . The structural carrier of claim 3 , wherein the first material is selected from polybutylene terephthalate, and polyethylene terephthalate.
7 . The structural carrier of claim 3 , wherein the second material is a polyamide material or a polyurethane material.
8 . The structural carrier of claim 6 , wherein the first material includes one or more additives selected from minerals, reinforcing fiber, hydrophobic silica, calcium carbonate, tabular alumina, or any combination thereof.
9 . The structural carrier of claim 1 , wherein the at least one insert is free of any contact with the foamable material prior to foaming of the foamable material.
10 . The structural carrier of claim 1 , wherein the at least one insert is free of any contact with the foamable material after foaming of the foamable material.
11 . The structural carrier of claim 4 , wherein the first material and the second material are molded together in a multi-shot injection molding process.
12 . The structural carrier of claim 1 , wherein the first material is formed first and later insert molded within the second material.
13 . The structural carrier of claim 1 , wherein the second material also forms the two or more reinforcing member segments.
14 . A hydroformed tube comprising the structural carrier of claim 1 .
15 . The structural carrier of claim 1 , wherein the two or more reinforcing member segments are solid and free of any cavities formed within.
16 . The structural carrier of claim 1 , wherein the two or more reinforcing member segments include a cavity that is free of any foamable material prior to or after foaming.
17 . The structural carrier of claim 4 , wherein at least a portion of the two or more reinforcing member segments lie in direct planar contact with the at least one insert.
18 . The structural carrier of claim 10 , wherein the two or more reinforcing member segments, not inclusive of the at least one insert, are separated from one another by at least 1 cm.
19 . The structural carrier of claim 18 , wherein the two or more reinforcing member segments, not inclusive of the at least one insert, are separated from one another by less than 10 cm.
20 . The structural carrier of claim 1 , wherein the two or more reinforcing member segments are identical in size and shape.