Shaped expandable material

1. A method of reinforcing a structure of an article of manufacture, the method comprising:

providing an initially solid pellet of expandable material including a first curing agent and having a self supporting characteristic during expansion thereof that is due to the presence of the first curing agent causing partial curing of the expandable material during processing of the pellet, and the inclusion of the following in the expandable material:

i) an acrylonitrile butadiene styrene copolymer material; and

ii) a thixotropic or fibrous filler;

injection molding the expandable material into a part;

inserting the part into a cavity that is at least partially defined by a structure of the article of manufacture; and

activating the expandable material to cure due to the presence of a second coring agent, so that the expandable material expands to a volume that is less than 500% relative to its original unexpanded volume and adheres to walls of the structure and provide structural reinforcement to the structure.

2. A method as in claim 1 wherein the expandable material is substantially tack-free to the touch.

3. A method as in claim 1 wherein the part, upon activation, forms a foam that exhibits a compressive strength greater than about 5 Mpa.

4. A method as in claim 1 wherein the part is skeletal.

5. A method as in claim 1 wherein the article of manufacture is an automotive vehicle.

6. A method as in claim 1 wherein the parts are substantially without supports and molded camera upon insertion into the cavity.

7. A method as in claim 1 wherein the expandable material is at least 90% by weight of the part upon insertion of the part into the cavity.

8. A method as in claim 1 wherein the part shaped of expandable material is a tubular structure with internal ribs, both the tubular structure and the ribs being formed of e expandable material and substantially maintaining its shape during expansion.

9. The method of claim 1 , wherein the expandable material is not in liquid form prior to partial curing.

10. A method of reinforcing a structure of an automotive vehicle, the method comprising:

providing an initially solid pellet of expandable material including a first curing agent and having a self supporting characteristic during expansion thereof that is due to the presence of the first curing agent causing partial curing of the expandable material during processing of the pellet, and the inclusion of the following in the expandable material:

i) an acrylonitrile butadiene styrene copolymer,

ii) an elastomer and

iii) a fibrous filler;

injection molding the expandable material into a part;

inserting the part into a cavity that is at least partially defined by a structure of the automotive vehicle; and

activating the expandable material to cure due to the presence of a second curing agent, so that the expandable material expands to a volume that is less than 500% relative to its original unexpanded volume and adheres to walls of the structure and provide structural reinforcement to the structure wherein the part substantially maintains it's shape during expansion.

11. A method as in claim 10 wherein the expandable material is substantially tack-free to the touch.

12. A method as in claim 11 wherein the part, upon activation, forms a foam that exhibits a compressive strength greater than about 5 Mpa.

13. A method as in claim 12 , wherein the part is skeletal and substantially maintains its skeletal shape during expansion.

14. A method as in claim 12 wherein the parts are substantially without supports and molded carriers upon insertion into the cavity.

15. A method as in claim 10 wherein the expandable material is at 90% by weight of the part upon insertion of the part into the cavity.

16. A method as in claim 10 wherein the part shaped of expandable material is a tubular structure with internal ribs, both the tubular structure and the ribs being formed of the expandable material.

17. A method of reinforcing a structure of an automotive vehicle, the method comprising:

providing an initially solid pellet of expandable material including a first curing agent and having a self supporting characteristic during expansion thereof that is due to the presence of the first curing agent causing partial curing of the expandable material or fast cure time of the expandable material and the inclusion of the following in the expandable material:

i) an acrylonitrile butadiene styrene copolymer:

ii) a butadiene-acrylonitrile elastomer and

iii) wollastonite;

injection molding the expandable material into a part having a tubular shape with internal ribs;

inserting the part into a cavity that is at least partially defined by a structure of the automotive vehicle; and

activating the expandable material to cure due to the presence of a second curing agent, so that the expandable material expands to a volume that is less than 500% relative to its original unexpanded volume and adheres to walls of the structure and provides structural reinforcement to the structure.

18. A method as in claim 17 wherein:

i. the expandable material is substantially tack-free to the touch; and

ii. the part, upon activation, forms a foam that exhibits a compressive strength greater than about 5 Mpa.

19. A method as in claim 18 wherein:

i. the parts are substantially without supports and molded carriers upon insertion into the cavity; and

ii. the expandable material is at least 95% by eight of the part upon insertion of the part into the cavity.

20. The method, of claim 18 , wherein the expandable material is not in liquid form prior to partial curing.