Multiple stage deformation reinforcement structure for impact absorption

1. A structural reinforcement for a vehicle comprising:

a) a carrier having:

(i) a base wall;

(ii) a first portion having a plurality of first projections extending from the base wall, wherein the plurality of first projections include two first portion opposing side walls and a plurality of bridging walls extending between the two first portion opposing side walls;

(iii) a second portion having a plurality of second projections extending from the base wall, wherein the plurality of second projections include two second portion opposing side walls and a plurality of ribs therebetween, and wherein at least some of the plurality of first projections has a height greater than a height of at least some of the plurality of second projections;

(iv) a plurality of openings formed in the base wall, wherein at least one of the plurality of openings is in the first portion and located between some of the plurality of first projections, and wherein at least another of the plurality of openings is located in the second portion between some of the plurality of second projections;

b) an activatable material affixed to the carrier, wherein the activatable material is configured to secure the carrier in a cavity of the vehicle, wherein a portion of the activatable material is located within an interior of the second portion, and wherein a portion of the activatable material is located on an exterior of the second portion;

wherein in event of an impact, the plurality of first projections and the plurality of second projections are configured to deform toward the base wall, in a direction of an impact load, or both in response to the impact load; and the plurality of first projections are configured to receive the impact load and deform before the plurality of second projections receives the impact load and deforms.

2. The structural reinforcement of claim 1 , wherein the carrier is a molded polymeric carrier.

3. The structural reinforcement of claim 2 , wherein the molded polymeric carrier includes at least one insert made of a material different than the molded polymeric carrier; and

wherein the material of the insert has a higher yield strength than a yield strength of the molded polymeric carrier.

4. The structural reinforcement of claim 1 , wherein the carrier is a single molded one-piece structure.

5. The structural reinforcement of claim 1 , wherein at least a portion of the carrier includes localized fiber reinforcement.

6. The structural reinforcement of claim 1 , wherein the activatable material is activated by heat in an automotive vehicle painting operation; and

wherein the activatable material is a structural foam, an acoustical foam, a sealant, or a combination thereof.

7. The structural reinforcement of claim 6 , wherein the activatable material expands upon activation.

8. The structural reinforcement of claim 1 , wherein the plurality of first projections have a similar height to one another; and

wherein the plurality of second projections have a similar height to one another.

9. The structural reinforcement of claim 1 ,

wherein the first plurality of projections include a pair of end walls opposing and distanced from one another, and wherein the bridging walls are located therebetween; and

wherein the pair of end walls are adjoining the two first portion opposing sidewalls to define a peripheral wall structure of the first portion which is generally continuous.

10. The structural reinforcement of claim 1 , wherein at least some of the first plurality of projections form one or more first cell-like structures extending from the base wall; and

wherein at least some of the second plurality of projections from one or more second cell-like structures extending from the base wall.

11. The structural reinforcement of claim 10 , wherein the first plurality of projections and second plurality of projections include one or more ribs, posts, tabs, extensions, or any combination thereof.

12. The structural reinforcement of claim 10 , wherein the deformation of the plurality of first projections, the plurality of second projections, or both in response to the impact load is plastic deformation.

13. The structural reinforcement of claim 12 , wherein the deformation of the plurality of first projections, the plurality of second projections, or both includes a buckling of the plurality of first projections, the plurality of second projections, or both.

14. A method for making the structural reinforcement according to claim 1 comprising:

a) performing finite element analysis to simulate the impact load;

b) generating a design of the carrier that has a structure according to claim 1 based upon results of the finite element analysis;

c) injection molding the carrier according to the design; and

d) locating the activatable material onto an external surface of the carrier.

15. A structural reinforcement for a vehicle comprising:

a) a carrier having:

(i) a base wall;

(ii) a first portion having a plurality of first projections extending from the base wall, wherein the plurality of first projections include two first portion opposing side walls and a plurality of bridging walls extending between the two first portion opposing side walls;

(iii) a second portion having a plurality of second projections extending from the base wall, wherein the plurality of second projections include two second portion opposing side walls and a plurality of ribs therebetween, and wherein at least some of the plurality of first projections has a height greater than a height of at least some of the plurality of second projections;

(iv) a plurality of openings formed in the base wall, wherein at least one of the plurality of openings is in the first portion and located between some of the plurality of first projections, and wherein at least another of the plurality of openings is located in the second portion between some of the plurality of second projections;

b) an activatable material affixed to the carrier, wherein the activatable material is configured to secure the carrier in a cavity of the vehicle, wherein a portion of the activatable material is located within an interior of the second portion, and wherein a portion of the activatable material is located on an exterior of the second portion;

wherein in event of an impact, the plurality of first projections and the plurality of second projections are configured to deform toward the base wall, in a direction of an impact load, or both in response to the impact load; and the plurality of first projections are configured to receive the impact load and deform before the plurality of second projections receives the impact load and deforms; and

wherein the carrier is a single molded one-piece structure;

wherein the activatable material is an expandable material which expands upon activation; and

wherein the first plurality of projections form one or more first cell-like structures and wherein the second plurality of projections form one or more second cell-like structures.

16. The structural reinforcement of claim 15 , wherein the carrier is a molded polymeric carrier.

17. The structural reinforcement of claim 15 , wherein the activatable material is a structural foam, an acoustical foam, a sealant, or a combination thereof.

18. The structural reinforcement of claim 17 , wherein the first plurality of projections and the second plurality of projections include one or more ribs, posts, tabs, extensions, or any combination thereof.

19. The structural reinforcement of claim 18 , wherein the plurality of first projections have a similar height to one another.

20. The structural reinforcement of claim 19 , wherein the plurality of second projections have a similar height to one another.