The invention relates to a frame, comprising, on each of its two sides relative to a vertical longitudinal center plane of the roof, a respective longitudinal beam made of sheet metal and at least one transverse beam made of sheet metal and connecting the two longitudinal beams to each other. The longitudinal beams and the at least one transverse beam are connected to each other via joint lines made of polyurethane foam. Moreover, a method for producing the frame is proposed.

Disclosed are various embodiments of an extruded expandable barrier, and various processes and systems for manufacturing the same. Using various extrusion processes to form an extruded expandable barrier allows for a reduction in tooling costs while also allowing more flexible barrier designs. Such designs can be specifically tailored for a particular cavity or cavities to ensure that the barrier fills the cavity after expansion. In addition, design changes can occur with little to no tooling changes.

An assembly useful for providing structural reinforcement and/or sound/vibration damping to a hollow member of a motor vehicle is provided which contains an injection-molded carrier made of a heat resistant thermoplastic composition, at least one of the first side and the second side of the carrier has at least one receptacle adapted to receive and retain an insert comprised of a heat-expandable resin composition. The carrier may have a plurality of openings in at least one of the first side or the second side forming a grid or lattice and the assembly may include a mounting member adapted to fasten the carrier to an interior wall of a hollow member.

The present disclosure relates to an insulation member for a hollow space of a vehicle bodywork. The insulation member comprises an expandable insulation body and a gas-impermeable cover. The cover comprises a yieldable chamber portion enclosing the expandable insulation body, wherein a pressure inside the chamber portion in a non-expanded state of the insulation member is less than atmospheric pressure. The cover further comprises at least one attachment portion adapted for attachment to the vehicle bodywork. The disclosure further relates to a vehicle comprising the insulation member, a use of the insulation member, a method of manufacturing an insulation member and a method of mounting an insulation member.

A structural reinforcement for insertion into a cavity of a vehicle structure including a base reinforcing portion, an expandable material and a localized reinforcement is disclosed. The localized reinforcement is placed within the structural reinforcement at a location of anticipated increased deformation during vehicle impact in an effort to reduce deformation and control the load distribution post-impact.

A baffle for sealing a vehicle structure, comprising a carrier with an interior body portion characterized by a plurality of spaced-apart members, providing voids, and an expandable material, that may also have openings, disposed on the carrier which, upon expansion, fills a vehicle cavity and covers the interior body portion and each of the voids.

A side sill rigidity reinforcement structure for a vehicle is mounted an inside surface of a side sill of the vehicle, thereby improving rigidity against side collision. the side sill rigidity reinforcement structure includes: a side sill inner 11, a side sill outer 12 disposed outside the side sill inner 11 and bonded to the side sill inner 11, and a side sill reinforcement member 20 installed in a space between the side sill inner 11 and the side sill outer 12. In particular, the side sill reinforcement member 20 has a plurality of portions each having a closed section formed to penetrate in the width direction of the vehicle, and the portions are repeatedly formed in the longitudinal direction of the vehicle.

A baffle or reinforcer includes a carrier configured to be disposed in a cavity and a fixation mechanism disposed on the carrier and configured to at least partially support the carrier in the cavity. The fixation mechanism defines an opening for receiving an expandable material. The fixation mechanism has an anti-return device configured to prevent at least a portion of the expandable material from escaping through the opening during expansion. A method includes inserting the carrier into the cavity, injecting the expandable material into the cavity via the opening in the fixation mechanism, expanding the expandable material within the cavity, and preventing at least a portion of the expandable material from escaping through the opening during expansion.

In one aspect of the invention there is provided a method of manufacture of an assembly comprising: forming an assembly by coupling a first component (150) to a second component (110) in spaced apart relationship therewith by means of coupling means (131); providing thermally activated seal means between the components, the first component, second component and seal means being arranged such that a gap exists between the first and second components allowing fluid flow therethrough; and subjecting the assembly to heat thereby to cause the seal means to expand and bridge the gap between the first and second components thereby to form a fluid tight seal between them. The second component may be at least partially enclosed between the first and a third component (161), and the second component may provide an aperture at a location opposite a portion of the third component whereby expansion of a seal means (112S,114S) around the aperture causes the aperture to be sealed by the seal means and said portion of the third component.

A fiber-reinforced plastics component includes a component plastics body, which defines at least parts of a plastics component, and at least one fiber-reinforced rod. The component plastics body is formed at least partially from plastics foam and at least partially surrounds the at least one fiber-reinforced rod in positively locking fashion.