Enhancement device

Abstract

The teachings of the present invention provide a reinforcement for a cavity. The reinforcement may include a carrier having a length extending along an axis between a first end and a second end. The carrier may include one or more longitudinal structures and one or more transverse structures. The carrier may also include one or more walls connected together to form one or more cavities extending along the axis. The carrier may have a cross-sectional shape that roughly corresponds to the cross-sectional shape of the interior of the hollow structural member. The device may also include a second material placed on the carrier. The second material is configured to expand, seal, enhance, or a combination thereof when a selectable stimulus is applied, and adhere to the interior of the cavity to provide reinforcement of the cavity.

Description

Technical Field

[0001] The teachings of the present invention are based on providing a reinforcement system and method for reinforcing and / or sealing a cavity. The reinforcement system includes a carrier having a plurality of ribs and / or a honeycomb structure and may include one or more restrictors for assisting in the placement, positioning and / or limiting the movement of a second material on the carrier. Background Art

[0002] Over the years, some industries, especially the transportation industry, have been concerned with providing reinforcement and sealing for articles such as transportation vehicles. Thus, a variety of materials and components for providing such functional attributes have been developed. Further, there is a continuous need to improve vehicle performance in the event of a collision or other impact, while maintaining or improving competing requirements, such as vehicle weight and fuel efficiency. A specific aspect that has been proposed is the impact of collisions on the front, rear and / or side body panels and pillars, and preventing the automobile body panels and pillars from deforming toward the passenger compartment. Although standard heavier metal reinforcements provide effective structural reinforcement, they can cause the vehicle to be heavier and less fuel efficient. Therefore, there is a need for structural reinforcement in the vehicle, which allows the vehicle to meet the increasingly stringent restrictions on collision impact requirements and fuel efficiency requirements.

[0003] The present teachings seek to provide improved reinforcement and / or sealing means for providing such functional attributes. Summary of the invention

[0004] The present teachings provide improved systems and methods for reinforcing and / or sealing hollow components.The present teachings include one or more unique carrier configurations and a secondary material disposed thereon for providing structural reinforcement and / or sealing.

[0005] The teachings of the present invention can provide a device including various layers of different materials. The device may include a carrier having a length extending along an axis between a first end and a second end. The carrier may have a longitudinal axis and may include one or more structures arranged in a direction perpendicular to the longitudinal axis, parallel to the longitudinal axis, or arranged at an oblique angle relative to the longitudinal axis. The carrier may also include one or more walls connected together to form one or more cavities (e.g., wells) extending along the axis. The carrier may have a cross-sectional shape that roughly corresponds to the cross-sectional shape inside the hollow structural member. The device may also include one or more second materials placed on the carrier. The second material may be an adhesive, a sealant, a foam, or some combination thereof. The second material may be an activatable material so that the material is configured to expand, seal, enhance, or a combination thereof when an optional stimulus is applied. When activated, the second material may foam, adhere, solidify, or some combination thereof so that the cavity of the receiving device is fully sealed and / or enhanced. The device may include one or more guide features located on the carrier or integrated with the carrier. One or more guide features may be configured to receive the second material and limit and / or guide the movement of the second material relative to the carrier.

[0006] The device can include one or more guide features (e.g., flow restrictors) that are integrally formed with the carrier to form a unitary structure. The one or more guide features are configured to limit the movement of the activatable material relative to the carrier. The system can also include one or more attachment portions located at the first end, the second end, or both of the carrier. The one or more attachment portions can be configured to engage the hollow structural member, connect to an additional device, or both.

[0007] It should be appreciated that other features and aspects of the present teachings include methods of forming devices as described herein, methods of reinforcing structural members, and the like. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1A A perspective view of a first surface of an exemplary reinforcement device in accordance with the teachings of the present invention is shown.

[0009] Figure 1B Shown with Figure 1A A perspective view of a second surface of a reinforcement device opposite to a first surface.

[0010] Figure 2A Shows Figure 1A A perspective view of the central part of the device is shown.

[0011] Figure 2B Shows Figure 1B A perspective view of the central part of the device is shown.

[0012] Figure 3AA perspective view of a first surface of an exemplary reinforcement device in accordance with the teachings of the present invention is shown.

[0013] Figure 3B Shown with Figure 3A A perspective view of a second surface of a reinforcement device opposite to a first surface.

[0014] Figure 3C Shows FIG. 3A to FIG. 3B A close up view of the attachment protrusion and terminal end of the device.

[0015] Figure 3D A close up view of an exemplary attachment portion in accordance with the teachings of the present invention is shown.

[0016] Figure 4 A perspective view of an exemplary apparatus in accordance with the teachings of the present invention is shown.

[0017] Figure 5 A perspective view of an exemplary apparatus in accordance with the teachings of the present invention is shown.

[0018] Fig. 6A A perspective view of a first surface of an exemplary device in accordance with the teachings of the present invention is shown.

[0019] Figure 6B Shows Fig. 6A A perspective view of an opposing second surface of the device is shown.

[0020] Fig. 7A A perspective view of a first surface of an exemplary device in accordance with the teachings of the present invention is shown.

[0021] Figure 7B Shows Fig. 7A A perspective view of an opposing second surface of the device is shown.

[0022] Figure 8 A perspective view of an exemplary apparatus in accordance with the teachings of the present invention is shown.

[0023] Fig. 9 A perspective view of an exemplary apparatus in accordance with the teachings of the present invention is shown.

[0024] Fig.10 A perspective view of an exemplary apparatus in accordance with the teachings of the present invention is shown.

[0025] Fig.11 A perspective view of an exemplary apparatus in accordance with the teachings of the present invention is shown.

[0026] Fig.12 A perspective view of an exemplary apparatus in accordance with the teachings of the present invention is shown.

[0027] Fig.13A perspective view of an exemplary apparatus in accordance with the teachings of the present invention is shown.

[0028] Fig.14 A perspective view of an exemplary apparatus in accordance with the teachings of the present invention is shown.

[0029] Fig.15 A perspective view of an exemplary apparatus in accordance with the teachings of the present invention is shown.

[0030] Fig.16A A perspective view of an exemplary apparatus in accordance with the teachings of the present invention is shown.

[0031] Fig. 16B Shown as Fig.16A A perspective view of the end of the device is shown.

[0032] Fig.17A A perspective view of a first surface of an exemplary device in accordance with the teachings of the present invention is shown.

[0033] Fig. 17B Shows Fig.17A A perspective view of a second opposing surface of the device is shown.

[0034] Fig. 17C Shown with Fig.17A The device is placed in contact with a second device.

[0035] Fig.18 A perspective view of an exemplary apparatus in accordance with the teachings of the present invention is shown.

[0036] Fig.19 A perspective view of an exemplary apparatus in accordance with the teachings of the present invention is shown.

[0037] Fig. 20 A perspective view of an exemplary apparatus in accordance with the teachings of the present invention is shown.

[0038] Fig.21 A perspective view of an exemplary apparatus in accordance with the teachings of the present invention is shown.

[0039] Fig.22A A perspective view of a first surface of an exemplary device in accordance with the teachings of the present invention is shown.

[0040] Fig. 22B Shows Fig.22A A perspective view of an opposing second surface of the device is shown.

[0041] Fig.23 A perspective view of an exemplary apparatus in accordance with the teachings of the present invention is shown.

[0042] Fig.24 A perspective view of an exemplary apparatus in accordance with the teachings of the present invention is shown.

[0043] Fig.25A A perspective view of an exemplary apparatus in accordance with the teachings of the present invention is shown.

[0044] Fig.25B Shows Fig.25A A close up view of the connector pins shown on the device.

[0045] Fig.25C It shows that Fig.25A A close up view of the central portion of the device is shown.

[0046] Fig.26A A perspective view of an exemplary apparatus in accordance with the teachings of the present invention is shown.

[0047] Fig.26B It shows that Fig.26A A close up view of the central portion of the device is shown.

[0048] Fig.26C It shows that Fig.26A A close up view of the top of the device is shown.

[0049] Fig. 27 A perspective view of an exemplary apparatus in accordance with the teachings of the present invention is shown.

[0050] Fig.28 A perspective view of an exemplary apparatus in accordance with the teachings of the present invention is shown.

[0051] Fig.29 A perspective view of an exemplary apparatus in accordance with the teachings of the present invention is shown. DETAILED DESCRIPTION

[0052] The teachings of the present invention meet one or more of the above needs through the improved devices and methods described herein. The explanations and descriptions given herein are intended to familiarize other technical personnel in the field with the present invention, its principles and its practical applications. Those skilled in the art can modify and apply the present invention in its various forms, such as the requirements that can be best suited to a particular purpose. Therefore, the specific embodiments of the teachings of the present invention set forth are not intended to be exhaustive or limit the teachings of the present invention. Therefore, the scope of the present invention should not be determined with reference to the above description, but should be determined with reference to the full scope of the attached claims and the equivalents of these claims. The disclosures of all articles and references (including patent applications and publications) are incorporated by reference for all purposes. Other combinations such as will be collected from the following claims are also possible, and the claims are also incorporated by reference in this written description.

[0053] This application claims the benefit of the filing date of U.S. Provisional Application Serial No. 62 / 858,628, filed on June 7, 2019, the contents of which are incorporated herein by reference for all purposes.

[0054] The teachings herein generally relate to structural reinforcement devices. The devices described herein may also provide functions such as sealing and blocking. The reinforcement devices described herein may be specifically adapted to provide sealing, blocking or reinforcement within a cavity of a vehicle. It is also contemplated that the reinforcement structure may be applied (e.g., assembled) to various articles, such as ships, trains, buildings, residences, furniture, etc. The term "vehicle" as used herein may be used to describe any transportation vehicle, including ships, trains, motor vehicles, airplanes, motorcycles, etc.

[0055] The device can be particularly used to absorb impacts associated with impact loads. Impact loads can be understood as forces generated by impacts to the surface of the vehicle, for example, during a collision. The impact load can be a side impact (passenger or driver side), a rear impact, or a front impact. The device can be used to reinforce the cavity of a body panel, a body pillar, an anti-collision beam, or elsewhere on the body. For example, the reinforcement structure can be arranged in the cavity of an A-pillar, a B-pillar, a C-pillar, a waistline, a front wall, a door panel, a frame system, a rear side panel, a front wall panel, a roof system, a door sill panel, a wheel cover, a windshield, the like, or any combination thereof. The device can absorb and distribute impacts so that at least a portion of the impact load is not transmitted to the passenger compartment.

[0056] The composite reinforcement includes a carrier. The carrier may include a device for fixing the structural reinforcement to a surface. The carrier may be formed to absorb and / or distribute energy from impact loads. The carrier may have any size, shape and / or configuration to fix the structural reinforcement to a surface, absorb and / or distribute energy from impact loads; provide a surface of a second material or any combination thereof. Features formed as part of the carrier may include a base structure and one or more protrusions. These features may be integrally molded or formed separately. The carrier may be a single-piece structure or may be composed of multiple pieces. The carrier may include one or more second materials, which may be located only on selected portions of the carrier, or may be positioned to substantially cover the entire carrier. The carrier may include one or more second material portions adjacent to each other. The carrier may include multiple protrusions. The carrier may include one or more honeycomb structures. The carrier may include one or more walls. The carrier may include one or more ribs. The carrier may include one or more holes (e.g., openings, orifices, or through holes). One or more walls may be formed by multiple protrusions. A carrier manufactured according to the teachings of the present invention may include one or more walls having a first surface and a substantially opposite second surface.

[0057] The carrier may include a plurality of protrusions. The plurality of protrusions may be used to secure the reinforcement to a surface, absorb and / or distribute energy from an impact load; provide a surface for receiving a second material, connect to other protrusions, help position the device into a cavity, or any combination thereof. The plurality of protrusions may be of any size, shape, and / or configuration. The plurality of protrusions may be walls, ribs, orifices, bridges, channels, bodies, attachments, reinforcements, or combinations thereof. Two or more of the plurality of protrusions may be connected and create one or more reinforcement honeycombs, one or more reinforcement cavities, one or more reinforcement cutouts, or combinations thereof.

[0058] The device may include one or more fasteners. One or more fasteners may be used to fix the composite reinforcement to a surface (e.g., one or more walls of a cavity) or to a second device. One or more fasteners may have any size, shape, or configuration to fix the structural reinforcement to a surface. The device may include a single fastener or multiple fasteners. One or more fasteners may be formed integrally with the carrier or separately from the carrier. One or more fasteners may be formed of the same material as the carrier or of a material different from the carrier. The device may include one or more fasteners positioned to correspond to an opening formed in the wall. The device may include one or more fasteners that cooperate with one or more edges of the cavity or the second device. One or more fasteners may include threaded fasteners, openings for receiving fasteners, tree fasteners, arrow fasteners, nail fasteners, clip fasteners, hook fasteners, friction fit fasteners, etc., or any combination thereof. One or more fasteners may be located in and / or through an opening in a surface (e.g., a cavity wall) to fix the structural reinforcement. One or more fastener receiving surfaces, such as protrusions protruding or extending from the cavity wall, or a second means, may be used to secure the structural reinforcement.

[0059] The device may include components made of one or more materials. The one or more materials may be any material that allows the carrier to absorb and / or distribute energy from the impact load; to have plastic deformation due to the impact load, to transfer the impact load from the first part to the second part, to allow the carrier to be integral, integrally formed, a one-piece structure, or any combination thereof. Suitable materials for the carrier may include, for example, but not limited to, polymer materials such as nylon or other polyamides, polysulfones, polyesters, polypropylene, polyethylene, polyurethanes, thermoplastic epoxies, sheet molding compounds, etc., which may be filled or unfilled (e.g., filled with glass, aramid or other reinforcing fibers); molded, extruded or otherwise shaped. The device (including the carrier) may include one or more metal components, such as aluminum, magnesium, steel and titanium, alloys, and even metal foams. The carrier (or any component of the device) may be formed of a thermosetting or thermoplastic polymer. The device may include a composite material, a woven material, a nonwoven material, or a combination thereof. The carrier may include at least one insert made of a different material from the carrier. For example, if the carrier is a molded polymer carrier, the insert may be made of a different material. The insert may have a yield strength higher than the molded polymer carrier. The yield strength may be measured according to ASTM D695 and / or ASTM D790. At least a portion of the carrier may include a local fiber reinforcement. The local fiber reinforcement may be woven, nonwoven, or a combination thereof. The carrier may also be formed of a molding compound such as a sheet molding compound (SMC), a block molding compound (BMC), a thick molding compound (TMC), etc. Exemplary compositions and formations of carriers are discussed in U.S. Patent Nos. 7,313,865 and 7,503,620, which are incorporated herein by reference for all purposes.

[0060] The device may include at least one portion or at least one component for receiving an impact load, absorbing and / or distributing energy from an impact load, transferring an impact load to another portion, reducing deformation of another portion, including multiple protrusions, deforming or collapsing in stages, residing in an opening of a cavity wall, or any combination thereof. The at least one portion or component may have any shape, size, or configuration to receive an impact load, absorb and / or distribute energy from an impact load, transfer an impact load to another portion, reduce deformation of another portion, including multiple protrusions, deforming or collapsing in stages, or any combination thereof. One or more portions or components for achieving such functions may be adjacent to one or more additional portions. For example, the carrier may include a first portion adjacent to a second portion. At least one portion (e.g., the first portion) may be located in the same cavity as the second portion or in an adjacent cavity. At least one portion (e.g., the first portion) may receive an impact load before the second portion. The first portion may absorb at least some of the energy of the impact load before transferring some of the impact load to the second portion. A portion may include multiple protrusions to absorb at least a portion of the impact load. The first portion may be connected to the second portion by at least one bottom wall. At least one first portion may extend, protrude or abut at least one second portion. The first portion may have a smaller cross section than the second portion. The cross section of the first portion may be at least 10%, 20%, 30% or even at least 50% smaller than the cross section of the second portion. The first portion with a smaller cross section may be adapted to fit the wall of the cavity. The first portion with a smaller cross section may extend through the wall of the cavity. For example, when inserted into the cavity, the first portion may be inserted through an opening on one side of the wall, and the second portion may be located on the opposite side of the wall. Insertion of a portion of the carrier through an opening may be found in U.S. Patent No. 6,607,238, which is incorporated herein by reference for all purposes.

[0061] The device may include a second material. The second material may be located on an outer surface of the carrier, in a cavity of the carrier, on an inner surface of the carrier, or some combination thereof. The second material may be activated to expand. The second material may have an expansion of 0% and 3000% or more when activated compared to the second material in its green state (e.g., before activation). Activation may be thermally triggered, however, other agents may be used to achieve activation by other means, such as moisture, radiation or other means. The second material may be a two-component material that activates when the two components are combined. This activation may occur at room temperature.

[0062] The second material may generally include a polymer material. Such a polymer material includes a polymer mixture, which may include a variety of different polymers, such as thermoplastics, elastomers, combinations of plastic bodies thereof, etc. For example (but not limited to), polymers that can be suitably incorporated into the polymer material include halogenated polymers, polycarbonates, polyketones, urethanes, polyesters, silanes, sulfones, allyls, olefins, styrenes, acrylates, methacrylates, epoxies, silicones, phenolic resins, rubbers, polyphenylene oxides, terephthalates, acetates (e.g., EVA), acrylates, methacrylates (e.g., ethylene methyl acrylate polymers), or mixtures thereof. Other possible polymer materials may be or may include, but are not limited to, polyolefins (e.g., polyethylene, polypropylene), polystyrene, polyacrylates, poly(ethylene oxide), poly(ethyleneimine), polyesters, polyurethanes, polysiloxanes, polyethers, polyphosphazenes, polyamides, polyimides, polyisobutylene, polyacrylonitrile, polyvinyl chloride, polymethyl methacrylate, polyvinyl acetate, polyvinylidene chloride, polytetrafluoroethylene, polyisoprene, polyacrylamide, polyacrylic acid, and polymethacrylate.

[0063] The polymeric material typically comprises a majority of the second material (e.g., up to 85% or greater by weight). Preferably, the polymeric second material comprises from about 15% to about 85%, more preferably from about 20% to about 70%, even more preferably from about 30% to about 65% by weight of two or more second materials.

[0064] It is possible that the polymer material may include one or more acrylates. Acrylates may include, for example, simple acrylates, methyl acrylates, ethyl acrylates, butyl acrylates, vinyl acrylates, copolymers or combinations thereof, etc. In addition, any of these acrylates may include other chemical groups such as epoxy resins, ethylene, butylene, pentene, etc., for forming compounds such as ethylene acrylate, ethylene methyl acrylate, etc., and additionally for forming copolymers or combinations thereof, etc. When included, one or more acrylates typically contain about 10% or less to about 95% or more of the polymer second material by weight, more preferably about 20% to about 85%, even more preferably about 35% to about 75%. An example of an acrylate is a copolymer of butyl acrylate and methyl acrylate, more particularly a copolymer of ethylene butyl acrylate and ethylene methyl acrylate. An example of such a copolymer is sold under the trade name LOTRYL 35BA40. Another example acrylate is an epoxy-modified (e.g., epoxidized) acrylate copolymer. An example of such a copolymer is sold under the trade name ELVALOY 4170.

[0065] It is also possible that the polymeric second material may include one or more acetates. The acetates may include, for example, acetate, methyl acetate, ethyl acetate, butyl acetate, vinyl acetate, copolymers or combinations thereof, and the like. In addition, any of these acetates may include other chemical groups such as epoxy, ethylene, butylene, pentene, and the like, for forming compounds such as ethylene acrylate, ethylene methyl acrylate, and the like, and additionally for forming copolymers or combinations thereof, and the like. When included, the one or more acetates typically comprise from about 5% or less to about 50% or more, more preferably from about 7% to about 35%, and even more preferably from about 15% to about 25% by weight of the polymeric second material.

[0066] An example of an acetate is ethylene vinyl acetate (EVA). An example of such an acetate is a relatively high ethylene content EVA sold under the trade name ESCORENE UL-7760. Another example of such an acetate is a relatively low molecular weight / low melt index EVA sold under the trade name ESCORENE UL-MV02514.

[0067] The polymeric second material may comprise a polyurethane-based foam or a phosphate-based foam. The phosphate-based foam may be derived from cashew nut shell liquid (CNSL).

[0068] The polymer second material may include epoxy resin. Epoxy resin is used herein to represent any conventional dimerization, oligomerization or polymerized epoxy material containing at least one epoxy functional group. The polymer-based material may be an epoxy-containing material having one or more oxirane rings that can be polymerized by a ring-opening reaction. For example, the second material may include up to about 20% of epoxy resin. In another example, the second material includes epoxy resin between about 0.1% and 50% by weight. The epoxy resin may be aliphatic, alicyclic, aromatic, etc. The epoxy resin may be provided as a solid (e.g., as a pellet, block, sheet, etc.) or a liquid (e.g., epoxy resin). The epoxy resin may include an ethylene copolymer or terpolymer that may have an alpha-olefin. As a copolymer or terpolymer, the polymer is composed of two or three different monomers, i.e., a small molecule with high chemical reactivity that can be connected to a similar molecule. In one example, epoxy resin is added to the second material to increase the properties of the material, such as adhesion, cohesion, etc. In addition, when the second material is a foamable material, the epoxy resin may enhance the honeycomb structure. The epoxy resin may be a phenolic resin, which may be a novolac type or other type of resin. The epoxy resin-containing material may include a bisphenol A epichlorohydrin ether polymer, or a bisphenol A epoxy resin that may be modified with butadiene or another polymer additive.

[0069] Various tackifiers or adhesives may be included in the second material. Exemplary tackifiers include, but are not limited to, resins, phenolic resins (e.g., thermoplastic phenolic resins), aromatic resins, synthetic rubbers, alcohols, and the like. According to a preferred embodiment, hydrocarbon resins (e.g., C5 resins, C9 resins, combinations thereof, and the like) are used as tackifiers. The hydrocarbon resins may be saturated, unsaturated, or partially unsaturated (i.e., having 1, 2, 3, or more degrees of unsaturation). An example of a preferred hydrocarbon resin is coumarone-indene resin. Another example of a preferred hydrocarbon resin is available under the trade name S-105 is sold. When used, the tackifier may comprise from about 0.1% or less to about 30% or more, from about 2% to about 25%, and even more preferably from about 6% to about 20% by weight of the two or more second materials. Advantageously, the tackifier can help control the cure rate to produce a more consistent or predictable expansion of the second material.

[0070] One or more foaming agents can be added to one or more second materials to produce inert gases, which form an open and / or closed honeycomb structure in the second material as required. In this way, the density of the article made of the second material can be reduced. In addition, material expansion helps to improve sealing ability, substrate wetting ability, adhesion to substrate, acoustic damping, combinations thereof, etc. The foaming agent can include one or more nitrogen-containing groups, such as amides, amines, etc. Examples of suitable foaming agents include azodicarbonamide, dinitropentamethylenetetramine, 4,4i-oxy-bis-(benzenesulfonic acid-hydrazine), trihydrazino-triazine and N, Ni-dimethyl-N, Ni-dinitroterephthalamide.

[0071] A promoter for the blowing agent can also be provided in one or more second materials. Various promoters can be used to increase the rate at which the blowing agent forms an inert gas. A preferred blowing agent promoter is a metal salt, or an oxide, such as a metal oxide, such as zinc oxide. Other preferred promoters include modified and unmodified thiazoles or imidazoles, urea, etc. The amount of the blowing agent and blowing agent promoter can vary widely in two or more second materials, depending on the type of desired cellular structure, the desired expansion amount of the second material, the desired expansion rate, etc. For example, depending on the desired volume expansion rate, the amount of the blowing agent, blowing agent promoter, or both in two or more second materials ranges from about 0% to about 25%, about 2% to about 20%, or even about 7% to about 15% by weight of the second material. It is expected that at least one of the two or more second materials can omit the blowing agent.

[0072] One or more curing agents and / or curing agent accelerators may be added to the two or more second materials. The amount of curing agent and curing agent accelerator may vary widely within the two or more second materials, as may the blowing agent, depending on the type of cellular structure desired, the amount of expansion desired for the blended thermoplastic material, the rate of expansion desired, the desired structural properties of the blended thermoplastic material, etc. For example, the amount of curing agent, curing agent accelerator present together in the one or more second materials is from about 0% to about 7% by weight.

[0073] The curing agent can assist in curing one or more second materials by crosslinking of the polymer, epoxy resin (e.g., by reacting a stoichiometric excess of the curing agent with epoxy groups on the resin), or both. It is also possible that the curing agent can assist in thermally curing one or more second materials. Useful curing agent categories can be selected from the following materials: aliphatic or aromatic amines or their respective adducts, amidoamines, polyamides, alicyclic amines (e.g., anhydrides, polycarboxylic acid polyesters, isocyanates, phenol-based resins (such as phenol or cresol novolac resins, copolymers such as those of phenol terpenes, polyvinylphenol or bisphenol-A formaldehyde copolymers, bishydroxyphenylalkanes, etc.), peroxides, or mixtures thereof. Particularly preferred curing agents include modified and unmodified polyamines or polyamides, such as triethylenetetramine, diethylenetriamine, tetraethylenepentamine, cyanoguanidine, dicyandiamide, and the like. Accelerators for the curing agent (e.g., modified or unmodified ureas, such as methylenediphenylbisurea, imidazoles, or combinations thereof) can also be provided for preparing the second material.

[0074] Although longer curing times are also possible, for the second material of the present teachings, curing times of less than 5 minutes, or even less than 30 seconds are possible. In addition, such curing times may depend on whether additional energy (e.g., heat, light, radiation) is applied to the second material or whether the material is cured at room temperature.

[0075] One or more second materials may also include one or more fillers or reinforcing components, including but not limited to particulate materials (e.g., powders), beads, microspheres, nanoparticles, etc. Fillers may include relatively low-density materials that generally do not react with other components present in one or more second materials. Examples of fillers and reinforcing components include silicon dioxide, diatomaceous earth, glass, clay, talc, pigments, colorants, glass beads or bubbles, carbon ceramic fibers, antioxidants, etc. Such reinforcing components, particularly clay, can help the second material to level itself during material flow. Available clays may include nanoparticles of clay and / or clays from kaolinite, illite, chlorite, montmorillonite or sepiolite groups that may be calcined. Examples of suitable fillers include but are not limited to talc, vermiculite, pyrophyllite, sauconite, saponite, nontronite, montmorillonite or mixtures thereof. Clay may also include a small amount of other ingredients, such as carbonates, feldspar, mica and quartz. Fillers may also include ammonium chloride, such as dimethylammonium chloride and dimethylbenzylammonium chloride. Titanium dioxide may also be used. One or more mineral or stone fillers such as calcium carbonate, sodium carbonate, etc. can be used as fillers. Silicate minerals such as mica can be used as fillers. It has been found that in addition to performing the normal function of fillers, silicate minerals and mica can improve the impact resistance of blended thermoplastic materials. When used, the filler in the second material can be 1% to 90% by weight of the second material. For example, the second material can include about 3% to about 30% by weight, and in another example about 10% to about 20% by weight of clay or similar fillers.

[0076] It is contemplated that one of the fillers or other components of the one or more second materials may be thixotropic to help control viscosity during activation and post-curing and thus control the flow of the material and properties in its green state such as tensile, compressive or shear strength.

[0077] The devices and related second materials described herein can be positioned in a cavity of a vehicle (e.g., a motor vehicle) before the vehicle is electrocoated. In the case where the second material is an activatable material, the material can be activated when heated during a paint shop baking operation. In applications where the activatable material is a heat-activated, heat-expandable material, an important consideration associated with the selection and formulation of materials containing the activatable material is the temperature at which the material reaction or expansion and possible curing will occur. More typically, the activatable material becomes chemically reactive at higher processing temperatures, such as those encountered in an automotive assembly plant, when the material is processed with automotive parts at elevated temperatures or at higher applied energy levels, such as during a paint or electrocoat curing or baking step. While the temperatures encountered in automotive assembly operations can be in the range of about 140°C to about 220°C (e.g., about 148.89°C to about 204.44°C (about 300°F to 400°F)), body and paint shop applications are typically about 93.33°C (about 200°F) or slightly higher. After the activatable material is activated, the material will generally cure. Thus, it is possible that the activatable material may be heated, which may then expand, and which may thereafter cure to form a resulting foamed material.

[0078] The devices described herein can be used to absorb energy in the event of an impact to a vehicle. The carrier can operate in a graded collapse in response to an impact load. Collapsing the carrier can include causing a first portion of the carrier to collapse before a second portion of the carrier. The first portion can collapse toward the second portion. The first portion can prevent or minimize collapse of the second portion. During the collapse, at least one first protrusion can plastically deform before at least one second protrusion plastically deforms in response to the impact load. After the at least one first protrusion is deformed to a specific height or other predetermined condition, the at least one second protrusion can receive a portion of the impact load.

[0079] Figure 1AA perspective view of a first surface 9 of a device 1 for reinforcing a vehicle cavity according to the teachings herein is shown. The device 1 includes a carrier 2 and a second material 4. The carrier has a first portion 6 with a first end 8 and a second portion 10 with a second end 12. The first end 8 and the second end 12 are located on opposite ends of the longitudinal axis 5 of the device. The first portion 6 extends from a midpoint 7 of the carrier to the first end 8. The second portion 10 extends from the midpoint 7 to the second end 12. The first portion 6 includes a recess 14 covered with the second material 4. The recess has a rectangular shape and is located between the first end wall 16 and the midpoint 7 of the carrier. The first portion 6 has a reinforcement 32 connecting the first end wall 16 and the first edge 20. The first edge 20 is convex. The reinforcement 32 is substantially free of the second material 4. A majority of the first portion 6 is filled with the second material 4, the second material 4 extending from the first edge 20 to the second edge 22 and from the first end wall 16 to the reinforcement 34. The first edge 20 extends along the longitudinal axis 5 of the carrier. The first edge 20 is substantially covered in the second material 4, except for the side bulkhead 28. The side baffle 28 is generally "V" shaped, having a first baffle edge 29 and a second baffle edge 30. The side baffle 28 is substantially free of the second material between the first baffle edge 29 and the second baffle edge 30. A plurality of ribs 31 covered in the second material 4 are located adjacent the second baffle edge 30 of the side baffle 28. The side baffle 28 is connected to a reinforcement cavity 34 at the midpoint 7 of the carrier 2. The reinforcement cavity 34 is substantially free of the second material, having a first wall 35 and a second wall 36. The second wall 36 of the reinforcement cavity has a recess 37 to accommodate a channel 38 ( Figure 1B ). The channel 38 is arranged between the midpoint 7 and the second end 12. Two access holes 39, 40 are located along the channel 38, each having an engagement member 42. The two access holes 39, 40 are connected by a channel 44 corresponding to the position of the channel 38. The area around the two access holes 39, 40 and the channel 44 on the first surface 9 is free of the second material.

[0080] Figure 1B The second surface 11 of the device 1 (with Figure 1A102 and 103. A perspective view of the first surface 11 (opposite to the first surface shown). Extending between the first end wall 16 and the transverse wall 76 are a plurality of reinforcing honeycombs 50 connected to longitudinal walls 78 disposed between the reinforcing honeycombs 50 along the longitudinal axis 5. The longitudinal walls 78 extend from the first end wall 16 to the second end 12 and stop at the transverse wall 76. The second material 4 is located on the second surface 11 between the transverse wall 76 and the transverse wall 145. The transverse wall 145 is separated to accommodate the channel 38. The reinforcements 33 and 144 are connected together and extend between the first side 21 and the wall 79. The reinforcement 144 at the first side 21 has two circular cutouts 102, 103. The channel 38 is located between the wall 79 and the second side 23. The channel 38 includes a channel guide 48, and the engaging member 42 is disposed between the channel guides 48.

[0081] Figure 2A A second end 12 of a second surface 11 including a channel 38 is shown. The channel 38 includes a first channel portion 141, a second channel portion 142, and a third channel portion 143. The channel 38 includes a set of guides 48 that help position the reinforcement structure with the door beltline. The first channel portion 141 and the third channel portion 143 have a second material 4 positioned therein. The second portion 142 includes two engaging members 42 positioned with access holes 39 and 40. The device 1 is configured to receive the door beltline into the channel 38 so that the engaging members 42 contact the beltline, thereby creating an interference fit. Once positioned with the beltline, and when activated, the second material 4 adheres the reinforcement structure to the vehicle.

[0082] Figure 2B A close up view of the first side 21 of the carrier 2 is shown. The side baffles 28 extend from the first edge 20 towards the second surface 11 but stop before contacting the second surface, allowing the second material to cover the remainder of the first side 21. The cutouts 102, 103 are located in the first side 21, cut into the ribs 31. The cutout 103 extends further into the wall 146. In this view, the first portion 141 and the second portion 142 of the channel 38 can be seen. The first portion 141 of the channel 38 is coated with the second material 4. The second portion 142 of the channel 38 includes a channel guide 48 with an engagement member 42 therebetween.

[0083] Figure 3AA perspective view of the device 1 is shown. The device comprises a carrier 2 and a second material 4. Both the carrier 2 and the attachment portion comprise a plurality of longitudinal and transverse reinforcing ribs 31, 41. The base 26 of the carrier 2 comprises a first end wall 16 and a second end wall 18, each end wall having an elevated edge. The second material 4 is selectively disposed on portions of the carrier 2, in particular between the reinforcing ribs 31. The base 26 of the carrier has a first reinforcement 32 and a second reinforcement 33. The first reinforcement comprises a top wall 51, a bottom wall 52, two side walls 53, 54, a pair of longitudinal ribs 41 and a pair of transverse ribs 43. The first reinforcement 32 extends from the first surface 9 towards the second surface 11 ( Figure 3B ). The perimeter of the reinforcement cavity 32 is raised to prevent the second material 4 from entering the cavity 32. Similarly, the perimeter of the second reinforcement 33 includes end walls 55, 56 and side walls 57, 58, which are raised to help position the second material 4 outside of the second reinforcement 33. The second reinforcement 33 is substantially free of the second material 4 between its walls and ribs. The first end wall 16 of the carrier and the end wall 51 of the first reinforcement 32 form a first surface channel 60 for the second material 4 to span the first surface 9 of the carrier 2. The end wall 52 and the end wall 55 of the second reinforcement 33 form a second surface channel 61 for the second material 4 on the carrier 2. The end wall 53 of the second reinforcement 33 and the second end wall 18 of the carrier 2 form a third surface channel 62 for the second material 4. The second material 4 surrounds the large transverse ribs 31 on the sides of the carrier 2.

[0084] Figure 3B The second surface 11 of the device 1 is shown. The second surface 11 has a first edge 20 and a second edge 22 between the first end wall 16 and the second end wall 18. The longitudinal walls 78, 79 are located in the central portion 19. A plurality of reinforcing cells 50 are disposed between the first edge 20 and the longitudinal wall 78, and between the second edge 22 and the longitudinal wall 79. The central portion 19 has reinforcing ribs 43 spanning between the walls 78, 79. A bridge 87 is disposed on the central portion 19 distal to the midpoint 7 and proximal to the first end wall 16. The second surface 11 of the device 1 includes attachment tabs 83 located at the first end 8 and the second end 12.

[0085] Figure 3C A close up view of the attachment tab 83 on the second end wall 18 of the device 1 is shown.

[0086] Figure 3DAn attachment portion 46 is shown. The attachment portion 46 consists of a plurality of longitudinal ribs 43 and transverse ribs 41 which are free of the second material. The attachment portion 46 tapers from the second end wall 18 of the carrier 2 towards the mounting location 137. The attachment portion 46 has a generally triangular shape. The attachment portion 46 includes a mounting location 137 having at least one engagement member 42. The engagement member 42 is configured to produce an interference fit when engaged. The mounting location 137 is quite far from the body of the device 1.

[0087] Figure 4 A device 1 is shown that can be used to reinforce the area around the windshield consistent with the teachings herein. The device 1 includes a carrier 2 and a second material 4. The carrier has a curved profile with a first portion 6 and a second portion 10. The first portion 6 and the second portion 10 each include an inner portion 21 and an outer portion 23. The outer portion 23 of both the first portion 6 and the second portion 10 includes a plurality of reinforcing ribs 31. The outer portion 23 of the first portion 6 includes a first circular protrusion 64 and a second circular protrusion 65, each extending from the outer portion 23 to the inner portion 21. A raised channel 66 is disposed within the circular protrusions 64, 65. The second portion 10 includes a trapezoidal aperture 67 in the carrier 2. The raised channel 66 in the first portion 6 and the trapezoidal aperture 67 of the second portion 10 are free of the second material 4. The outer portion 23 of the second portion 10 has a semicircular opening 68. The semicircular opening 68 is surrounded by a curved wall 69. The curved wall 69 includes a cavity 34 with a first mounting hole 70. Two additional mounting holes 71, 72 are located between the ribs 31 in the second portion 10. The interior 21 and facing surface 25 of the first part 6 and the second part 10 are substantially coated in the second material 4. The interior 21 of the first part 6 has a recess 37. The carrier comprises a first attachment piece 47 and a second attachment piece 49. The first attachment piece 47 is inserted into the piece fixing piece 59 on the distal end of the first part 6, and the second attachment piece 49 is inserted into the piece fixing piece 59 on the distal end of the second part 10.

[0088] Figure 5An apparatus 1 consistent with the teachings herein is shown that can be used to reinforce an area around a windshield. The apparatus 1 includes a carrier 2 and a second material 4. The carrier has a curved profile with a first portion 6 and a second portion 10. The first portion 6 and the second portion 10 each include a first edge 20 and a second edge 22. The first edge of both the first portion 6 and the second portion 10 includes a plurality of reinforcing ribs 31 extending into the carrier. The second edge 22 of the first portion 6 and the second portion 10 is substantially coated in the second material 4. The first edge 20 includes a semicircular opening 68, the interior of which is substantially free of the second material 4. Located between the first edge 20 and the second edge 22 of the carrier 2 are a plurality of elliptical through holes 75. The through holes 75 are disposed between the reinforcing ribs 31 on the first edge 20 and the second material 4 on the second edge 22. The carrier 2 also includes a plurality of mounting holes 70 along the longitudinal axis 5 of the first portion 10 and the second portion 10. The plurality of mounting holes 70 are disposed between the first edge 20 and the second edge 22. The distal end of the first portion 6 of the carrier 2 includes an end wall 16 extending perpendicular to the longitudinal axis 5 of the first portion. The end wall 16 intersects with the transverse wall 76. The transverse wall 76 is adjacent to the end wall 16. Disposed between the transverse wall 76 and the second edge 22 is an aperture 67. The aperture 67 is located on the second edge 22 between the end wall 16 and the transverse wall 76 extending into the carrier. A plurality of reinforcing honeycombs 50 connect the end wall 16 and the transverse wall 76. The plurality of reinforcing honeycombs 50 follow the contour of the aperture 67. The carrier comprises a first attachment sheet 47 and a second attachment sheet 49. The attachment sheets 47, 49 are inserted into the sheet fixing 59.

[0089] Fig. 6A A perspective view of a first side 21 of a reinforcement structure 1 formed as an upper B-pillar reinforcement consistent with the teachings herein is shown. The reinforcement structure 1 has an elongated carrier 2 having a slight taper from a first end 8 to a second end 12. The second end 12 is generally "t" shaped, with a second end wall 18 perpendicular to the longitudinal axis 5. The second end 12 tapers from the second end wall 18 toward a midpoint 7 of the carrier 2. The width of the tapered portion of the second end 12 decreases. The carrier 2 includes a plurality of reinforcing ribs 31 extending from the first edge 20 to the longitudinal wall 78 and from the second edge 22 to the longitudinal wall 79. The central portion 19 is located between the walls 78, 79 and rises along the longitudinal axis 5. The height of the carrier 2 decreases angularly from the wall 78 toward the first edge 20 and from the wall 79 toward the second edge 22. The plurality of ribs 31 also have an angled profile connecting the longitudinal walls 78, 79 to the first edge 20 and the second edge 22, respectively. The central portion 19 comprises a quadrilateral aperture 67 which extends from the first surface 9 through the reinforcing structure 1 to the second surface ( Figure 6B). The quadrilateral opening 67 is located proximal to the first end 8 of the reinforcement structure 1 and distal to the midpoint 7. The carrier comprises a reinforcement honeycomb 50, which is located proximal to the second end 12 of the reinforcement structure 1 and distal to the midpoint 7. The central portion 19 of the carrier 2 comprises a plurality of through holes 75 of different sizes and shapes.

[0090] Figure 6B A perspective view of the second surface 11 of the device 1 is shown. The second surface 11 on the carrier 2 comprises longitudinal walls 78, 79 extending from the first end wall 16 to the transverse wall 76 in the second end 12. The reinforcing ribs 41 are located between the transverse wall 76 and the second end wall 18. A plurality of reinforcing ribs 31 extend between the longitudinal walls 88, 89. At the first end 8, a plurality of reinforcing cells are located between the walls 88, 89.

[0091] Fig. 7A A perspective view of a first side 21 of an apparatus 1 formed as an upper B-pillar reinforcement consistent with the teachings herein is shown. The apparatus 1 includes a carrier 2 and a second material 4. The carrier 2 has a first portion 6 and a second portion 10. The first portion 6 is a generally elongated portion extending from a first end 8 to a second end 12. The second portion 10 is a mounting portion having an end wall 18 at the second end 12. The second end wall 18 is perpendicular to the longitudinal axis 5. The second end wall includes an attachment protrusion 83. The second portion 10 is connected to the carrier 2 along a transverse wall 76. Both the first portion 6 and the second portion 10 have a first side 21 having a curved profile extending from the first end 8 to the second end 12. The first portion 6 has a plurality of ribs 31 extending from the first side 21 to a central portion 19 of the carrier 2, and a plurality of ribs 31 extending from the second side 23 to the central portion 19. The plurality of ribs 31 are perpendicular to the longitudinal axis 5. The central portion 19 is defined by longitudinal walls 78, 79, which form an area of ​​a first abutting mass 80 containing the second material 4. Several recesses 14 are located in the central portion 19. The longitudinal walls 78, 79 and the plurality of ribs 31 together accommodate the second material 4 to certain portions of the carrier 2. A second adjacent block 81 of the second material is located on the second portion 10, extending proximally from the second end wall 18 towards the midpoint 7. The second block 81 of the second material 4 follows a curved profile along the first edge 20. The second portion 10 has a plurality of reinforcing cells away from the transverse wall 76, with semicircular reinforcements 82 disposed therebetween. The second end wall 18 protrudes away from the carrier 2. The second end wall 18 has a plurality of reinforcing ribs 41 extending along the second end wall 18. The first end wall 16 has a raised edge 24 around the distal end of the wall. Attached to the first end wall 16 is an attachment tab 47.

[0092] Figure 7BA perspective view of the second side 23 of the device 1 is shown. The second portion includes a plurality of ribs 41 connecting the second portion to the first portion. The second material 4 is located on the facing surface 25 of the second end wall 18. The first portion 6 includes longitudinal walls 88, 89 forming a central portion 19. A plurality of ribs 31 are disposed between the walls 88, 89. Reinforcements 32, 33 are connected to the longitudinal wall 88 and extend toward the first edge 20. The reinforcements 32, 33 are surrounded by the second material 4. The cutout portion 37 of the longitudinal wall 88 abuts against the distal end of the reinforcement 33 toward the first end 8. The wall 88 protrudes from the notch 37 toward the first edge 20 having a circular protrusion 64. Similarly, the longitudinal wall 89 includes a circular protrusion 65 extending toward the second edge 22. The reinforcement 34 is connected to the longitudinal wall 89 and extends from the longitudinal wall 89 toward the second edge 22. The reinforcement 34 is separated by the ribs 43.

[0093] Figure 8 A perspective view of a middle C-pillar device 1 is shown. The device 1 includes a carrier 2 and a second material 4. The carrier 2 has a first end 6 and a second end 10, and has a first edge 20 and a second edge 22. The first end 8 and the second end 12 each include an attachment tab 47, 49. The attachment tabs 47, 49 are inserted into a tab fixture 59. The carrier 2 has a generally curved profile. The activatable material 4 follows the first edge 20 along the profile of the carrier 2. The first edge 20 includes two protrusions 63, one protrusion is positioned toward the first end 6 and the other protrusion is positioned toward the second end 12. A plurality of ribs 31 extend from the second edge 22 of the carrier 2 toward the first edge 20, terminating at a partition wall 27. The carrier 2 includes a raised channel 66 extending from the first surface 9 to the second surface 11 between the partition wall 27 and the second edge 22. A reinforcement cavity 34 is located proximal to the second end 10, extending from the partition wall 27 toward the first edge 20. The reinforcement cavity 34 is surrounded on three sides by the second material 4. A raised channel 86 extending from the first surface 9 to the second surface 11 is located within the reinforcement cavity 34 .

[0094] Fig. 9A perspective view of a lower B-pillar device 1 is shown. The device 1 includes a carrier 2 and a second material 4. The carrier 2 has a first end 8 and a second end 12, and has a first edge 20 and a second edge 22. The first end 8 includes a first end wall 16 that protrudes beyond the first edge 20. The protruding portion of the first end wall 16 has a quadrilateral shape, protruding outward from the first side 21. The first end wall 16 and the first side 21 are coated with the second material 4. Extending from the first end wall 16 is an attachment piece 47 connected to the end wall by a connecting arm 45. Similarly, a second attachment piece 49 is located on the second edge 22 extending away from the carrier 2, near the second end wall 18. The carrier 2 includes a plurality of reinforcing ribs 31. The plurality of reinforcing ribs 31 extend from the first edge 20 and the second edge 22 toward a central channel 19. The central channel 19 is defined by a pair of longitudinal channel walls 78, 79 located between the second end wall 18 and a transverse wall 76. The transverse wall 76 is connected between the first edge 20 and the second edge 22. The central channel 19 is filled with the second material 4.

[0095] Fig.10 1 is a perspective view of a lower A-pillar reinforcement structure 1. The reinforcement structure 1 has a first end 6 and a second end 10, and has a first edge 20 and a second edge 22. The reinforcement structure 1 has a generally triangular shape. The first end 8 is much wider than the second end 12. The first end wall 16 includes a circular portion extending proximally to the second end 12. Walls 78, 79 extend angularly from the circular portion of the first end wall 16 to the second edge 22, forming a central portion 19 of the reinforcement structure 1. The central portion 19 has a first rib-shaped portion 84 and a second rib-shaped portion 85. A bridge 87 is disposed between the first rib-shaped portion 84 and the second rib-shaped portion 85. The end of the bridge 87 facing the first edge 20 terminates in a recess 14 having a second material 4. The end of the bridge facing the second edge is adjacent to a first connecting plate 90 disposed in a first surface 9 of the reinforcement structure. The first connecting plate 90 is recessed below the first surface 9. At the second edge 22, the first end wall 16 has a circular cutout 64, and a second connecting plate 91 is disposed in the circular cutout 64. Immediately adjacent the circular cutout 64 on the second edge 22 is the notch 37. From the notch 37 to the second end wall 18, the second edge 22 is straight. Moving from the second end wall 18 toward the first end 6, the first edge 20 includes a first straight portion 13 and a second straight portion 15 connected by a curved transition 17. The curved transition 17 extends the first edge 20 outwardly so that the second straight portion 15 extends further away from the longitudinal axis 5 than the first straight portion 13. Disposed along the first edge 20 in the second straight portion 15 is a reinforcement notch 92 having an attachment tab 47.

[0096] Fig.11A perspective view of a middle B-pillar device 1 consistent with the teachings herein is shown. Device 1 includes a carrier 2 and a second material 4. Carrier 2 includes a first portion 6 and a second portion 10 connected together by a connector portion 93. A first end wall 16 extends through the first portion 6, the connector portion 93, and the second portion 10. A first edge 20 extends from the first end wall 16 to the second end wall 18. A reinforcement 33 extends distally from the second end wall 18. At the first portion 6, an attachment tab 47 is connected to the first end wall 16. A second attachment tab 49 is connected to the reinforcement 33 on the second end 12. Proximate the first end wall 16 is a circular depression 17. At the midpoint 7 of the carrier, a reinforcement cavity 34 spans from the first portion 6 to the second portion 10, spanning the connection portion 93 of the carrier 2. The reinforcement cavity 34 includes a reinforcement rib 41 that longitudinally connects one side of the cavity to the other side. The reinforcement cavity 34 is free of the second material 4. The first end 8 of the second portion 10 is aligned with the first portion 6 along the first end wall 16. The reinforcement 32 is connected to the first end wall 16 on the second portion 12. The reinforcement 32 is sunken into the surface of the second portion 12, and the orifice 94 is located in the center of the reinforcement 32. The second end 12 of the second portion 10 and the connecting portion 93 are close to the second end 12 of the first portion 6. The raised channel 66 is located proximal to the second end 12 of the second portion 10 and distal to the reinforcement cavity 34.

[0097] Fig.12 A perspective view of a middle C-pillar device 1 is shown. The device 1 includes a carrier 2 and a second material 4. The carrier 2 has a first portion 6 and a second portion 10, and has a first edge 20 and a second edge 22. The first portion 6 is generally curved and the second portion 10 is generally straight. The first end wall 16 includes an attachment piece 47. The second end wall 18 is arranged across the carrier and includes an attachment piece 49 connected thereto. The carrier has reinforcements 32, 33, 34 arranged in the first surface 9, each reinforcement extending from the second edge 22 toward the first edge 20. The reinforcements 32, 33, 34 are separated by a longitudinal wall 78. The reinforcement 33 is located approximately halfway between the first end wall and the second end wall at the midpoint 7 of the carrier 2. Surrounding the reinforcements 32, 33, 34 is the second material 4. A depression 14 having a part-circular shape extends from the first edge 20 toward the second edge 22. Two holes 70, 71 are located in the first surface 9. The second surface 11 of the carrier 2 includes a channel 61 extending along the longitudinal axis 5.

[0098] Fig.13A perspective view of an apparatus 1 for reinforcing a rocker panel is shown. The apparatus 1 includes a carrier 2 and a second material 4. The carrier 2 includes a first end 8 and a second end 12. Extending between the first end 8 and the second end 12 is a pair of longitudinal walls 78, 79 forming a central portion 19. The central portion 19 includes a plurality of reinforcing cells 50 disposed between the longitudinal walls 78, 79. Between the plurality of reinforcing cells 50 is a connector 45. The second material 4 extends from the walls 78, 79 to edges 20, 22 covering a first side 21 and a second side (not shown). Reinforcements 32, 33 are disposed in the first edge 20 and the first side 21 of the carrier 2. Connected to the first end wall 16 and the first edge 20 in the first side 21 is a recessed reinforcement 34. The transverse wall 31 extends into the first side 20.

[0099] Fig.14 A perspective view of an upper A-pillar device 1 is shown. The device 1 has a generally curved profile. The device 1 is constructed of a carrier 2 and a second material 4. The carrier 2 has a first end 8 and a second end 12, and a first edge 20 and a second edge 22. The first edge 20 and the second edge 22 are elevated and extend between a first end wall 16 and a second end wall 18. A longitudinal wall 78 extends between the first end wall 16 and the second end wall 18 with the same curvature as the carrier 2. The longitudinal wall 78 is located approximately halfway between the first edge 20 and the second edge 22. The second material 4 is located between the first end wall 16, extending to the second end 12, between the longitudinal wall 78 and the second edge 22. A plurality of ribs 31 extend from the first edge 20 to the longitudinal wall 78. A plurality of holes 95 are provided between the first edge 20 and the longitudinal wall 78, between some of the ribs 31. A central hole 96 is located approximately at the midpoint 7 of the carrier 2. Two angled supports 97 are connected to the first edge 20 and the ribs 31 around the central hole 96. The second end 12 of the carrier 2 has an attachment assembly 98 that protrudes away from the first surface 21. The attachment assembly 98 includes an interference fit connector 93. The attachment assembly is located at the second end 12, connects to the first edge 20 to the second edge 22, and extends from the second end wall 18.

[0100] Fig.15 A perspective view of a first surface 9 of a composite frame structure 1 is shown. The composite frame structure 1 includes a carrier 2 and a second material 4. The carrier 2 has a curved profile between a first end 8 and a second end 12. An angle plate 99 extends angularly from a first edge 20 to a second edge 22, away from the carrier 2. A plurality of reinforcing ribs 31 are located between the first end 8 and the second end 12. The ribs 31 extend through the angle plate 99, terminating at rails 100, 101. The first edge 20 and the second edge 22 are coated with the second material 4. The rails 100, 101 are each coated with the second material 4. The second surface 11 has an attachment rail 138 extending from the first end 8 to the second end 12.

[0101] Fig.16Ais a perspective view of a composite frame system 1. Composite frame system 1 includes a carrier 2 and a second material 4. A first end 8 and a second end 12 have a first edge 20 and a second edge 22. Carrier 2 tapers from first end 8 and second end 12 toward a midpoint 7 of carrier 2. Wall 78 extends along longitudinal axis 5 of carrier 2. Wall 78 separates carrier 2 between first side 9 and second side 11. Carrier 2 includes two material cutouts 102, 104 in first end 8 and material cutouts 103, 105 in second end 12. Material cutouts 102, 103 are located on first side 11 between wall 78 and first edge 20 and are free of second material 4. Material cutouts 104, 105 are located in second side 12 of carrier 2 between second edge 22 and wall 78. Cutouts 103, 105 are outlined with second material 4. Second side 11 of carrier 2 includes a plurality of mounting holes 70 adjacent second edge 22. The first side 11 of the carrier 2 has a plurality of reinforcing ribs 31 extending from the first edge 20 at an angle to the wall 78. A rounded portion of the wall 78 extends from the first side 9 into the second side 11. The second side 11 of the carrier 2 is substantially coated with the second material 4 from the wall 78 to the second edge 22.

[0102] Fig. 16B yes Fig.16A A close up view of the second end 12 of the composite frame system 1 is shown. The second material 4 extends past the second edge 22 and onto the facing surface 25 of the second edge 22. The second side of the carrier is substantially coated with the second material 4 except around the perimeter of the cutout 103.

[0103] Fig.17AA perspective view of a first surface 9 of a reinforcement structure 1 for an upper B-pillar consistent with the teachings herein is shown. The reinforcement structure 1 has a first end 8 and a second end 12. The reinforcement structure includes a first longitudinal body 107 and a second longitudinal body 108 extending between the first end 8 and the second end 12. The longitudinal bodies each include a plurality of support buttons 106. The first longitudinal body 107 and the second longitudinal body 108 each include an inner edge 109 and an outer edge 110. The longitudinal bodies 107, 108 taper from the first end 8 toward the second end 12, decreasing in width. The longitudinal bodies 107, 108 are connected by reinforcement ribs 31, 43 and bridges 87, 113, 114. The reinforcement rib 31 is located at the first end 8 and the bridge 87 is located at the second end 12. The reinforcement rib 43 is located at the midpoint 7 of the carrier. The recess 14 is located at the proximal end of the bridge 87 spanning between the inner edges 109 of the two longitudinal bodies 107, 108. The bridge 113 has two cutouts 102, 103, each of which contacts the inner edge 109 of the longitudinal body 107, 108, respectively. At the distal end of the bridge 113 is a recess 14. The bridge 114 is located between the reinforcing rib 43 and the bridge 87. Both bridges 113, 114 include a circular protrusion 64 connected to the reinforcing wall 76, which extends across the bridge 114 to the body 107, 108. The second material 4 coats the inner edge 109 of the longitudinal body 107, 108, the bridge structure and the ribs.

[0104] Fig. 17B A perspective view of the second surface 11 of the device 1 is shown. The carrier 2 is coated with a second material 4 on the inner edge 109 and the reinforcing ribs 31, 43 and bridges 87, 113, 114. On the first surface 9, the recesses 14 protrude towards the second surface 11, forming protrusions 65.

[0105] Fig. 17C Shown with Fig.17A The reinforcement structure 1 is placed in contact with the frame 115. The frame 115 has a shape that substantially matches the reinforcement structure 2 between the inner edges 109 of the two longitudinal bodies 107, 108. The frame 115 includes a connector 45. The frame 115 is coated with a second material 4.

[0106] Fig.18A perspective view of a wheel cover reinforcement device 1 is shown. The device 1 includes a carrier 2 and a second material 4. The carrier has a first portion 6 with a first end wall 16 and a second portion 10 with a second end wall 18. The first portion 6 includes reinforcing ribs 31 arranged on both sides of a central portion 19 of the first portion 6. Reinforcing ribs 41 are connected to the first wall 78 of the central portion 19 and to the second wall 79 of the central portion 19, respectively. The central portion 19 is coated with the second material 4. There are two apertures in the central portion 19, one is a square aperture 67 and the other is a circular aperture 94. Immediately adjacent to the square aperture 67 is a connecting barb 83. The first portion 6 and the second portion 10 of the carrier 2 share a common wall 116 and a second edge 22. The second portion 10 of the carrier 2 is connected to the first portion at a partition wall 27. A first reinforcement 32 extends from the partition wall 27 to the second portion. The first reinforcement is separated by the reinforcing ribs 31. The second reinforcement is located at the second end wall 18 and the common wall 116. The first reinforcement 32 is adjacent to the second reinforcement 33, such that the first reinforcement 32 is perpendicular to the second reinforcement 33. The square aperture 67 is located between the first reinforcement 32 and the second reinforcement 33. The oval aperture 77 is located between the square aperture 67 and the first edge 20 in the second portion 10. The second portion 10 of the carrier 2 is coated with the second material 4 around the first reinforcement 32 and the second reinforcement 33, and extends along the second end wall 18 toward the partition wall 27. The second portion 10 includes a connecting barb 83.

[0107] Fig.19is a perspective view of a composite door reinforcement system 1. The device 1 includes a carrier 2 and a second material 4. The device 1 has a generally quadrilateral shape. The device 1 has a first end 8 and a second end 12, and has a first side 21 and a second side 23. The first end 8 includes a first end wall 16, which extends from the first side 21 to the second side 23 and is generally straight. The first end wall 16 includes a recessed portion 118 that protrudes proximally into the carrier 2. The first end wall 16 also includes a connector 45 extending distally from the first end 8. The connector 45 has an elliptical hole 77 to facilitate mounting of the device 1. At the proximal end of the first end wall 16, from the connector 45, a circular wall 69 connects the first edge 20 to the first end wall 16. The second end 12 of the carrier includes a second end wall 18 extending between the first side 21 and the second side 23. The first side 21 of the carrier 2 extends farther distally than the second side 23, so the second end wall 18 is angled to connect the two sides 21, 23. The first end 8 is formed by a series of reinforcing ribs 31, 41 that intersect each other to reinforce the structure between the first edge 20 and the second edge 22. The second end 22 of the carrier 2 is generally straight and includes a reinforcing protrusion 83 extending away from the carrier. The second end 12 includes a plurality of reinforcing ribs 43 extending proximally from the second end wall 18 toward the inner wall 119. A portion of the second end 12 includes a recess 14 and is coated with a second material 4. Extending from the second side 23 to the first end 8 is an internal attachment area 120. The internal attachment area 120 includes a material cut 102 surrounded by a reinforcing perimeter 121. Two attachment tabs 47, 49 are connected to the reinforcing perimeter 121 located in the cut 102. The attachment tabs 47, 49 are coated with the second material 4. The first tab is perpendicular to the longitudinal axis 5 and the second tab is at an angle relative to the longitudinal axis 5. An orifice with a raised edge 66 is connected to the corner of the cut 102 that is closest to the first edge 20 toward the first end 8. The second aperture 94 is located distally of the cutout 102, towards the second end 12. The second aperture 94 comprises a raised edge and is connected to the through hole 75. The carrier comprises a plurality of through holes 75 adjacent to the first edge 20. The first edge 20 of the carrier 2 is coated with the second material 4 from the first side 21 to the second side 23.

[0108] Fig. 20A perspective view of an upper C-pillar device 1 is shown. The device 1 includes a carrier 2 and a second material 4. The carrier 2 has a first end 8 and a second end 12, and a first edge 20 and a second edge 22. The first end 8 stops at a first end wall 16. The first end wall 16 has a facing surface 25 coated with the second material 4. The first end wall 16 extends between the first edge 20 and the second edge 22. The first end wall 16 is proximally bent toward the second edge 22. The second edge 22 extends between the first end 8 and the second end 12. The second edge 22 includes a recessed portion 118 so that the edge moves proximally at the midpoint 7 of the carrier 2. A connecting arm 123 extends axially from the second edge 22. The connecting arm 123 includes a reinforcing connector 45 attached to the first surface 9 of the carrier 2. Two connecting barbs 83 extend downwardly from the connecting arm 123. At the second end 12 of the carrier 2, the second edge 22 is connected to the second end wall 18 at an angle upward. The second end wall 18 extends between the first edge 20 and the second edge 22. The first edge 20 is divided into three parts 124, 125, 126. The first part 124 of the first edge 20 moving proximally from the second end wall 18 is stepped with three rounded parts 127 angled proximally from the second end wall 18 and away from the second edge 22. The second part 125 of the first edge 20 has a recessed area 118 that protrudes into the carrier 2 toward the second edge 22. The second part 125 of the first edge 20 is connected to the first part 124 and the third part 126, transitioning downwardly to the first part 124 and upwardly to the third part 126. The third part 126 is generally planar. The carrier includes a guide 122 protruding from the facing surface 25.

[0109] Fig.21 A perspective view of the device 1 is shown. The device 1 includes a carrier 2 and a second material 4. The carrier 2 has a first end 8 and a second end 12. The first end 8 includes a first end wall 16, and the second end 12 includes a second end wall 18. A body 26 of the carrier 2 extends between the first end wall 16 and the second end wall 18. The body 26 includes a first surface 21. A plurality of reinforcing ribs 31 extend outwardly from the first surface 21, connecting the track 100 to the body 26. The track 100 is attached to the first end wall 16. A connector 45 extends from a cutout 102 in the body 26, further securing the track 100 to the body 26. A reinforcing channel extends from the first surface 9 of the carrier 2 to the second surface (not shown) between the first edge 20 and the second edge 22. The channel at the second edge 22 is stepped, connecting one side of the channel to the other side along the second edge 22. The bottom of the channel extends through the second edge 22 of the carrier 2. The first surface 9 is coated with the second material 4. Adjacent to the first end wall 16 is an aperture 94 through the first surface 9 to the second surface 11.

[0110] Fig.22AA perspective view of a first side 9 of a composite door system structure 1 is shown. The structure 1 includes a carrier 2 and a second material 4. The carrier 4 has a first portion 6 and a second portion 10. The first portion 6 has a generally longitudinal profile and the second portion 10 has a curved profile. The curved portion 17 extends between the first end 8 and a top edge 128 of the first portion 6. The curved portion 17 includes a notch 37 along its length. The first end 8 includes an attachment portion 46 having an attachment tab 83 and a guide 122 surrounded by a reinforcement 32. Under the attachment portion 46 is a channel 95. The second portion 10 has a material cut 102 located between the curved portion 17 and the edge 129. Connected to the material cut 102 is an aperture 94. A semicircular opening 68 protrudes into the second portion 10 along a bottom edge 132 of the second portion 10. The bottom edge 132 of the second portion 10 is connected along the top edge 128 of the first portion 6. The first portion 6 has a first end wall 16 and a second end wall 18. The second end wall 18 is rounded to a bottom edge 130. The longitudinal wall 78 extends from the second end wall 18 toward the first end wall 16. The transverse wall 76 perpendicularly intersects the longitudinal wall 78. The second material 4 is placed between the longitudinal wall 78 and the bottom edge 130, and between the first end wall 16 and the transverse wall 76.

[0111] Fig. 22B yes Fig.22A 1. A perspective view of a second side of a composite door system structure of FIG. 1. The second portion 10 is reinforced with a plurality of reinforcing honeycombs 50 along the curved portion 17. An attachment tab 133 is located at a bottom edge 132 of the second portion 10. A second material 4 is positioned throughout the first portion 6 and the second portion 10, disposed around the reinforcement structures 32, 50, channels 94, 95, and cutout 102. A channel is formed in the top edge 128 of the first portion 6 to accommodate the attachment tab 133 on the second portion 10. The material cutout 103 is located in the top edge 128 of the first portion 6. Reinforcement cutouts 104, 105 extend downwardly from the longitudinal wall 78 and between the first end wall 16 and the transverse wall. A reinforcing rib 31 separates the two cutouts 104, 105.

[0112] Fig.23An apparatus 1 for a top cover system consistent with the teachings herein is shown. The apparatus 1 includes a carrier 2 and a second material 4. The carrier 2 has a first end 8 and a second end 12, and a first edge 20 and a second edge 22 extend between the first end 8 and the second end 12. The first edge 20 is coated with the second material 4 and extends outward from the carrier 2 at approximately the midpoint 7. The recess 17 is located at the first edge 20 and the midpoint 7. The recess 17 is free of the second material 4. The raised orifice is located between the recess 17 and the second end 12. The guide 122 extends from the first edge 20. The first end 8 has an L-shape. The first end wall 16 is connected perpendicularly to the longitudinal wall 78. The reinforcement 32 is connected to the first end wall 16 and the second edge 22. The longitudinal wall 78 is connected to the reinforcement 33. The second end 12 has a second end wall 18, which is connected to the second edge 22 by a stepped wall 139 of the reinforcement cavity 140. The reinforcement cavities 34, 144 are connected to the second edge 22 and are located between the stepped cavity 140 and the reinforcement 33. Immediately adjacent the distal end of the reinforcement cavity 144 is the attachment tab 83 .

[0113] Fig.24 An apparatus 1 for a frame system consistent with the teachings herein is shown. The apparatus 1 includes a carrier 2 and a second material 4. The carrier 2 has a first end wall 16 and a second end wall 18 connected by a first edge 20 and a second edge 22. A guide 122 extends from the carrier 2 at the first end 8 and the second end 12. A plurality of reinforcing honeycombs 50 extend from the longitudinal wall 78 to the first edge 20 between the first end wall 16 and the second end wall 18. The first side 21 is connected to the first edge 20 and is coated with the second material 4. The second material 4 covers the carrier between the longitudinal wall 78 and the second edge 22. Connectors 45 are located at both ends of the carrier 2. A connector pin 134 is shown inserted into the connector 45 on the second end 12 of the carrier 2.

[0114] FIG. 25A to FIG. 25C An apparatus 1 for a frame system consistent with the teachings herein is shown. Fig.25A1 is a perspective view of the device 1. The device 1 includes a carrier 2 and a second material 4. The carrier has a first end 8 with a first end wall 16 and a second end 12 with a second end wall 18. A guide 122 extends from the end walls 16, 18. The first edge 20 and the second edge 22 are arranged between the first end wall 16 and the second end wall 18. The longitudinal walls 78, 79 extend between the first end wall 16 and the second end wall 18. Between the longitudinal walls 78, 79 are reinforcing honeycombs 50. The guide 122 is located on a plurality of reinforcing honeycombs 50. The connector 45 is located on both ends 8, 12 between the first edge 20 and the longitudinal wall 78. The connector pin 134 is shown inserted into the connector 45 on the first end 8. The second material 4 is located on the carrier 2 from the longitudinal wall 79 to the second edge 22 and from the second edge 22 across the second side 23. The semicircular reinforcement 82 is located in the second edge 22 extending into the first surface 9 and the second side 23. The double raised cutout 135 extends into the second side 23 and the second surface (not shown). Fig.25B A close up view of the first end 8 is shown, showing the connector pin 134 inserted into the connector 45 . Fig.25C A close up view of the semi-circular reinforcement 82 and the double raised cutout 135 is shown. The semi-circular reinforcement 82 and the double raised cutout 135 are adapted to slide over a weld nut or the like when the device is located within the cavity.

[0115] FIG. 26A to FIG. 26C A perspective view of a device 1 for use in a frame system consistent with the teachings herein is shown. Device 1 includes a carrier 2 configured to receive a second material (not shown). Carrier 2 has reinforcements 32, 33, 34. Reinforcements 32, 34 are located between first edge 20 and midpoint 7. Reinforcement 32 is generally square, while reinforcement 34 is generally polygonal. Reinforcement 33 is located between midpoint 7 and second edge 22. Reinforcement 33 has an elongated bottom wall 56 that protrudes at an angle away from first surface 9 of carrier 2. Channel 38 is located inside reinforcements 32, 33, 34 to guide the flow of the second material. Channel 60 is located outside reinforcements 32, 33, 34. Along first end 8, reinforcement 32 includes a connector pin 134 that is inserted into connector 45.

[0116] Fig.26B A portion of the second surface 11 of the device 1 is shown, focusing on the channel 61. The channel 61 allows the activatable material to flow into a designated location. The activatable material flowing through the channel 60 on the first surface 9 passes through the carrier 2 along the channel 61 to the second surface 11.

[0117] Fig.26C A close up view of the reinforcements 33, 34 and channels 38, 60 on the first surface 9 is shown.

[0118] Fig. 27An apparatus 1 for a steering system consistent with the teachings herein is shown. The apparatus 1 comprises a carrier 2 and a second material (not shown). The carrier 2 has an octagonal shape. The first end wall 16 of the carrier 2 is shown as having a concave plate 112 with a central channel 96.

[0119] Fig.28 An apparatus 1 for a door reinforcement system consistent with the teachings herein is shown. The apparatus 1 includes a carrier 2 and a second material (not shown). The carrier has a first end 8 and a second end 12. The second end 12 has an arm 123 extending axially from the carrier 2. The arm 123 has a connecting plate 90 with a mounting hole 70 and a guide 122. The first side 21 of the carrier 2 includes a protrusion 136 extending axially from the first surface 9. The protrusion of the first surface 9 is curved, starting from the first end wall 16 and terminating at the second end wall 18. The protrusion 136 is bent from the first end wall 16 and the first edge 20 into the carrier 2. The first end wall 16 and the second end wall 18 both extend axially together with the protrusion 136. A second mounting hole 71 is provided in the carrier 2. The second mounting hole 71 is higher than the first surface 9.

[0120] Fig.29 An apparatus 1 for use in a cowl system consistent with the teachings herein is shown. The apparatus 1 includes a carrier 2 and a second material 4. The carrier 2 is generally wedge-shaped, having a first end 8 and a second end 12 and a first side 21 and a second side 23. The first side 21 includes a rib 41 along a first portion 6. The second side 23 is coated with the second material 4. An attachment tab 83 protrudes from the second side 23. The area directly surrounding the attachment tab 83 is free of the second material 4.

[0121] Any numerical value described herein includes all values ​​that increase progressively with one unit from a lower value to a higher value, provided that there is an interval of at least 2 units between any lower value and any higher value. As an example, if the value of the amount of the stated component or the process variable (such as temperature, pressure, time, etc.) is such as 1 to 90, 20 to 80 or even 30 to 70, then it is intended to clearly list values ​​such as 15 to 85, 22 to 68, 43 to 51, 30 to 32, etc. in this specification. For a value less than 1, a unit is considered to be 0.0001, 0.001, 0.01 or 0.1 as the case may be. These are only examples of specific intent, and all possible combinations of numerical values ​​between the lowest value and the highest value listed should be considered to be clearly stated in this application in a similar manner. It can be seen that the teaching of the amount represented by "parts by weight" herein also considers the same range represented by weight percentage. Thus, a statement in the detailed description regarding a teaching of a range of "x parts by weight of the resulting polymer blend composition" also encompasses a teaching of "x being the same recited amount range in terms of weight percent of the resulting polymer blend composition."

[0122] Unless otherwise specified, all ranges include both endpoints and all numbers between the endpoints. The use of "about" or "approximately" in connection with a range applies to both ends of the range. Thus, "about 20 to 30" is intended to cover "about 20 to about 30", including at least the specified endpoints.

[0123] The disclosures of all articles and references (including patent applications and publications) are incorporated by reference for all purposes. The term "consisting essentially of ... " used to describe a combination should include the elements, ingredients, components or steps identified, as well as such other elements, ingredients, components or steps that do not substantially affect the basic and novel characteristics of the combination. The combination of elements, ingredients, components or steps described herein using the terms "comprising" or "including" also encompasses instances that are substantially composed of elements, ingredients, components or steps. By using the term "may" herein, it is meant that any of the attributes that "may" be included are optional.

[0124] A plurality of elements, compositions, components or steps can be provided by a single integrated element, composition, component or step. Alternatively, a single integrated element, composition, component or step can be divided into separate multiple elements, compositions, components or steps. The disclosure of "one" or "an" describing an element, composition, component or step is not intended to exclude other elements, compositions, components or steps.

[0125] It should be understood that the above description is illustrative and not restrictive. Many embodiments and many applications other than the examples provided will be apparent to those skilled in the art after reading the above description. Therefore, the scope of the present invention should not be determined with reference to the above description, but with reference to the full scope of the appended claims and the equivalents of these claims. The disclosures of all articles and references (including patent applications and publications) are incorporated by reference for all purposes. The omission of any aspect of the subject matter disclosed herein in the appended claims is not a waiver of the subject matter, nor should it be considered that the inventor does not consider the subject matter to be part of the disclosed inventive subject matter.

Claims

1. A device for strengthening a cavity, comprising: a) a carrier having a length extending between a first end and a second end, the carrier comprising: one or more vertical structures; and one or more lateral structures located at one or more of the first end and the second end of the carrier, the lateral structures forming at least one carrier cavity; and a first portion and a second portion located within the at least one carrier cavity, and the first portion has a first cross-sectional thickness that is less than 50% of a second cross-sectional thickness of the second portion; and b) a second material comprising a tackifier and a two-component, room temperature curing, phosphate ester-based foam at least on the one or more longitudinal structures; Wherein the device is configured to be attached to the cavity via one or more mechanical fasteners, adhesives, or both.

2. The device according to claim 1, wherein: The carrier includes one or more rib structures.

3. The device according to claim 1 or claim 2, wherein: The carrier includes one or more reinforcing cavities.

4. The device according to claim 1, wherein: The one or more mechanical fasteners are located on the carrier.

5. The device according to claim 1, wherein: The carrier has one or more attachment portions for receiving the one or more mechanical fasteners.

6. The device according to claim 1, wherein: The device is configured to be slid into the cavity, wherein the one or more fasteners are placed into the device from the outside through a wall of the cavity.

7. The device according to claim 1, wherein: The one or more lateral structures are free of the second material.

8. The device according to claim 1, wherein: The one or more lateral structures are coated with the second material.

9. The device according to claim 2, wherein: The one or more longitudinal structures, the one or more transverse structures, or both are positioned to form one or more channels on the carrier.

10. The device according to claim 9, wherein: The one or more channels direct the second material to a desired location on the device.

11. The device according to claim 1, wherein: The carrier has a longitudinal profile.

12. The device according to claim 1, wherein: The carrier has a curved profile.

13. The device according to claim 9, wherein: The carrier includes one or more guides for positioning the device into the cavity.

14. The device according to claim 1, wherein: The carrier includes one or more longitudinal walls, one or more transverse walls, or both.

15. The device according to claim 1, wherein: The one or more longitudinal walls are connected to one or more transverse ribs.

16. The device according to claim 1, wherein The support comprises one or more pores.

17. The device according to claim 16, wherein: The carrier comprises one or more recesses in a surface of the carrier.

18. The device according to claim 17, wherein: The one or more recesses are filled with the second material.

19. The device according to claim 1, wherein: The second material omits a blowing agent.

20. The device according to claim 19, wherein The second material is a mixture of two or more second materials.

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