A structural assembly for a recreational vehicle includes a first structural frame member having a wall and a hollow space at least partially defined by the wall and a second structural frame member having a section thereof extended into the hollow space of the first structural frame member forming an internal interface with the wall of the first structural frame member. The assembly further includes a foam material located in the hollow space that fills a portion of the hollow space to thereby form a bearing member adjacent the section to restrict motion of the section relative to the wall and thereby to form an internal connection between the second structural frame member and the first structural frame member at the internal interface to secure the second structural frame member to the first structural frame member to form a recreational vehicle component.

A system for insulating a structural element in a motor vehicle including a structural element having a first constituent part and a second constituent part which are joined together at a first joining point and a second joining point and form a cavity. The system furthermore includes a device having a carrier and a first expandable adhesive, wherein the carrier is arranged on the first constituent part of the structural element by way of a fastening element. The system furthermore includes a second expandable adhesive which is arranged on the second constituent part of the structural element. In this case, the first expandable adhesive and the second expandable adhesive are configured, and arranged, in such a way that, after the adhesives have been expanded, the device and the second expandable adhesive substantially completely fill a cross section of the structural element.

A structural reinforcement comprising a rigid polymeric structure having a longitudinal axis and including a first portion having an opening for connecting the structure to a secondary surface and a second portion including a stop device having a terminal end that extends beyond any other surface of the structure, a fastening device for locating into the opening an adhesive associated with one or more of the first and second portion, wherein at least a section of the second portion lies in a plane that is skew to a plane in which the first portion lies.

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 structural reinforcement for a vehicle comprising: a) a carrier having a base wall from which a plurality of projections extend, the plurality of projections including at least one first projection and at least one second projection and the at least one first projection having a height greater than a height of the at least one second projection; b) an activatable material which is heat activatable and affixed to the carrier, configured to secure the carrier in a cavity of the vehicle; wherein in event of an impact, the at least one first projection and second projection are configured to deform toward the base wall and/or in a direction of an impact load in response to the impact load; and the at least one first projection is configured to receive the impact load and deform before the at least one second projection receives the impact load and deforms.

A method of forming a composite panel in-line is disclosed. The method includes the steps of forming a hot thermal plastic sheet of material and providing the hot thermal plastic sheet of material to a punch having punch members extending outwardly therefrom. The hot thermal plastic sheet of material is advanced through the punch in order to form apertures through the hot thermal plastic sheet of material such that each aperture extends from an outer surface of the hot thermal plastic sheet of material to an inner surface of the hot thermal plastic sheet of material. An outer metal sheet and an inner metal sheet, respectively, are coupled to opposing sides of the hot thermal plastic sheet of material.

An insulating element for sealing off a structural element in a motor vehicle includes a carrier and an expandable material that is arranged on the carrier. The insulating element has a top side and a bottom side, wherein at least three contact points are arranged on each of the top side and the bottom side, which are designed in such a way that, when a plurality of identical insulating elements are stacked, adjacent insulating elements respectively lie on one another via these contact points and are thus arranged parallel to one another.

A suspension mount comprising a carrier with a first portion and a second portion, an activatable material selectively disposed on the carrier, one or more bridges connecting the first portion and the second portion of the carrier, wherein the first portion and the second portion of the carrier each include one or more damper mounts, and wherein the first portion corresponds to a left side and the second portion corresponds to the right side so that the suspension mount is attachable to a vehicle in one direction.

A flooring system comprising: one or more structural members, each of the one or more structural members having opposing outer portions interconnected by ribs, the opposing outer portions and the ribs forming a plurality of channels within the one or more structural members along a length of each structural member.

A cavity sealing bulkhead part is provided comprising a first structural component, a second structural component and a hinge for producing a movable connection between the first structural component and the second structural component; the hinge comprising a first hinge component assigned to the first structural component and a second hinge component assigned to the second structural component, the first hinge component and the second hinge component being movable relative to one another about a shaft, at least one of the two hinge components comprising an expansion material that is convertible from an initial state into an expanded state by activation, and in the expanded state acting as a sealant between the first and second hinge components; and the bulkhead part being produced in a two-component injection molding process using a carrier material and the expansion material; also provided are methods for producing the bulkhead part.