WO2024226682A1

WO2024226682A1 - Reinforcement insert assembly with a structural spine

Info

Publication number: WO2024226682A1
Application number: PCT/US2024/026103
Authority: WO
Inventors: Bill BARZ; Eric White; Dennis SKONIECZNY
Original assignee: Zephyros Inc
Current assignee: Zephyros Inc
Priority date: 2023-04-24
Filing date: 2024-04-24
Publication date: 2024-10-31
Anticipated expiration: 2025-10-24
Also published as: CN121013807A

Abstract

An insert assembly (30) comprising a first insert member (40); a second insert member (40) arranged adjacent to the first insert member (40); an adhesive (48) disposed on at least a portion of the first or second members(40), or both; and at least one structural spine member (50) arranged in direct contact and attached to the first insert member (40) and to the second insert member (40) creating the insert assembly (30).

Description

REINFORCEMENT INSERT ASSEMBLY WITH A STRUCTURAL SPINE

CROSS-REFERENCE TO RELATED APPLICATION

[001] This application claims priority from U.S. Provisional Application No. 63/461 ,423 filed on April 24, 2023, and which is incorporated herein by reference in their entirety for all purposes.

FIELD OF THE INVENTION

[002] The present invention relates generally to a relatively long assembly of reinforcing inserts for use in vehicle frames, more particularly an assembly of reinforcing inserts containing a structural spine that ties the relatively long assembly of reinforcing inserts together for use in transportation vehicle’s body in white or chassis frames.

BACKGROUND OF THE INVENTION

[003] Vehicles can have relatively long spans in the chassis frame or in the Body In White (BIW) that may require additional support and reinforcing inserts. It may be a particularly pressing issue in EV (Electric Vehicle) frames/BIW in areas of the vehicle that hold or are adjacent to the battery packs. BIW/Frame members in these areas tend to be relatively long (e.g., greater than 1.0 meters), and may have higher crash performance requirements to protect the EV battery pack(s) located in the area.

[004] Smaller and localized structural frame inserts are believed to be well known. See e.g., U.S. Patent Nos. 6,467,834; 10,960,934; 11 ,565,755; 11 ,608,131 ; and United States Publication No. US2022/0315110, all incorporated by reference herein in their entirety for all purposes. However, there remains a need for BIW/frame members that are both lightweight and high strength while being easy to assemble and modify during production of the members and/or any vehicle assembly process.

SUMMARY OF THE INVENTION

[005] The present teachings meet one or more of the above needs by the improved devices and methods described herein. [006] In one aspect, the present teachings pertain to an insert assembly comprising: (i) a first insert member; (ii) a second insert member arranged adjacent to the first insert member; and (iii) at least one structural spine member arranged in direct contact and attached to the first insert member and to the second insert member creating the insert assembly.

[007] The teachings herein are further directed to an insert assembly comprising a first insert member, a second insert member arranged adjacent to the first insert member, an adhesive, structural material, sealing material, tape, or some combination thereof, disposed on at least a portion of the first or second members, or both; and at least one structural spine member arranged in direct contact and attached to the first insert member and to the second insert member creating the insert assembly.

[008] The at least one structural spine member may be comprised of a pultruded polymer with reinforcing fiber strands and configured as a single unitary component with a cross-shaped cross-section.

[009] The assembly may include a structural material, a sealing material, an adhesive, a tape, or some combination thereof along a portion of a periphery of one or more of the first insert member, the second insert member, or the at least one structural spine member.

[0010] The at least one structural spine member may be disposed in a channel of at least one of the first insert member and second insert member and wherein the channel has a complementary shape to the cross-shaped cross-section of the at least one structural spine.

[0011] The channel, the at least one structural spine member, or both, includes an adhesive for bonding a wall of the structural spine and insert to one another.

[0012] The assembly may include multiple spines located within the insert assembly.

[0013] An impact load may be distributed via the at least one structural spine member from the first insert member to the second insert member.

[0014] A cross-section of the spine member may have a curved shape, a T- shape, an M-shape, a W-shape, a V-shape, a U-shape, a circular shape, an oblong shape, a C-shape, and X-shape, an l-shape, or some combination thereof.

[0015] The spine member may have a length in the direction of a longitudinal axis of the assembly of at least 250 mm, at least 500 mm, or even at least 1000 mm. [0016] The spine member may have a length in the direction of a longitudinal axis of the assembly of at least 250 mm, at least 500 mm, or even at least 1000 mm.

[0017] The first insert member, the second insert member, or both may include a plurality of side walls and at least one side wall lies in direct planar contact with a vehicle cavity wall.

[0018] The first insert member, the second insert member, or both may include a plurality of side walls and a plurality of rib structures.

[0019] At least one rib structure may extend in a direction that is substantially perpendicular to at least one side wall.

[0020] The plurality of rib structures may have a rib height of at least about 10 mm, at least about 30 mm, or even at least about 50 mm.

[0021] The plurality of rib structures may have a rib width of at least about 5 mm, at least about 10 mm, or even at least about 20 mm.

[0022] The first insert member, second insert member, and/or spine member may include a mechanical fastener.

[0023] The first insert member, second insert member, and/or spine member may include a plurality of cell-like structures formed by side walls, ribs, or some combination thereof.

[0024] The first insert member, second insert member, and/or spine member may include one or more openings formed in a side wall, a rib, or some combination thereof.

[0025] The one or openings may receive a portion of a mechanical fastener.

[0026] The spine member may be substantially free of any direct contact with a vehicle cavity wall.

[0027] The channel may be formed by at least two rib structures.

[0028] At least a portion of the channel may be formed by a rib structure that splits into two rib structures with an opening therebetween that forms the channel. [0029] The assembly may include three or more insert members.

[0030] The length of each insert member measured along the longitudinal axis of the spine member may be less than 1000 mm, less than 500 mm, less than 100 mm, or even less than 20 mm.

[0031] Each insert member may be the same shape and size.

[0032] One or more insert member may differ in shape and size from another insert member. [0033] The length of the spine member along the longitudinal axis of the assembly may be longer than the combined length of all of the insert members.

[0034] Each insert member may be the same shape and size.

[0035] The channel may receive only a portion of the spine member.

[0036] The channel may receive the entirety of the spine member.

[0037] Each insert member may be substantially free of direct contact with any adjacent insert member.

[0038] One or more insert members may be in direct contact with one or more adjacent insert members.

[0039] One or more insert members may include a plurality of rib structures and the rib structures have a top edge that is substantially co-planar with the top edge of one or more adjacent rib structures.

[0040] One or more insert members may include a plurality of rib structures and the rib structures have a top edge that lies in a different plane than the top edge of one or more adjacent rib structures.

[0041] One or more insert members may include at least two side walls or even at least three side walls.

[0042] The insert members may be formed of a polyamide-based material.

[0043] The spine member may be formed of a polyurethane-based material.

[0044] The adhesive, structural material, sealing material, tape, or some combination thereof, may comprise a material adapted to expand upon exposure to a stimulus.

[0045] The assembly may include at least two different materials selected from adhesive, structural material, sealing material, tape, or some combination thereof, [0046] The adhesive, structural material, sealing material, tape, or some combination thereof, may comprise a two-part material.

[0047] The adhesive, structural material, sealing material, tape, or some combination thereof, may comprise a two-part material including an A-side and a 13- side, and wherein the B-side includes one or more phosphate esters.

[0048] The assembly may include a structural material that is epoxy-based.

[0049] The structural material may comprise polyvinyl butyral.

[0050] The structural material may have a strain to failure of greater than 2% and a modulus of at least 700 MPa as measured in accordance with ASTM D638 Type IV test method. [0051] The assembly may include a sealing material that is ethylene-based.

[0052] The adhesive, structural material, sealing material, tape, or some combination thereof, may have adhesive characteristics either in a green state (e.g., prior to any foaming and/or curing) or during foaming and/or curing).

[0053] The assembly may include including a two-part material that is injected into and/or around the assembly once the assembly is located in a desired location.

[0054] The assembly may include an adhesive located in between the insert members and spine member.

[0055] The assembly may include an adhesive located in between the insert members and spine member and a two-part material that is injected into and/or around the assembly once the assembly is located in a desired location.

[0056] The adhesive may be heat-activated to adhere and cure.

[0057] The adhesive, structural material, sealing material, tape, or some combination thereof may be adapted to foam, cure, and/or develop adhesive characteristics upon exposure to a stimulus selected from heat, moisture, or chemical activation.

[0058] The teachings herein are further directed to a method comprising pultruding an elongated spine member, molding one or more insert members to have a channel located therein and locating the elongated spine member into the channel.

[0059] The method may include overmolding the one or more insert members onto the elongated spine member.

[0060] The method may include locating an adhesive in between the elongated spine member and one or more insert members to adhere the one or more insert members to the spine member.

[0061] The method may include locating the elongated spine member and one or more insert members into a vehicle cavity.

[0062] The method may include injecting a two-part material onto and/or around the elongated spine member and one or more inserts.

DESCRIPTION OF THE DRAWINGS

[0063] Fig. 1 is a perspective view of an illustrative EV with the frame assembly (BIW) in accordance with the present teachings. [0064] Fig. 2 is a perspective view of an illustrative EV with the frame assembly (chassis) in accordance with the present teachings.

[0065] Fig. 3A is a sectional view of an illustrative insert assembly in accordance with the present teachings (Cross-shaped spine).

[0066] Fig. 3B is a sectional view of another illustrative insert assembly in accordance with the present teachings (C-shaped spine).

[0067] Fig. 4 is a close-up perspective view of an illustrative insert assembly 3A in accordance with the present teachings.

[0068] Fig. 5 is a perspective view of an illustrative insert assembly with outer wall of the frame hidden in accordance with the present teachings.

[0069] Fig. 6 is a perspective view of another illustrative insert assembly with the outer wall of the frame hidden in accordance with the present teachings.

[0070] Fig. 7 and 8 are schematical representations of various vehicle test requirements.

[0071] Fig. 9 is a perspective view of an illustrative insert assembly with a snap together feature in accordance with the present teachings.

DETAILED DESCRIPTION

[0072] The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the invention, its principles, and its practical application. The specific embodiments of the present invention as set forth are not intended as being exhaustive or limiting of the invention. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. Other combinations are also possible as will be gleaned from the following claims, which are also hereby incorporated by reference into this written description.

[0073] The teachings herein may generally relate to the inventive reinforcement insert assemblies used in the cavities of structural frame assemblies (in an automobile chassis or BIW). The inventive reinforcement insert assemblies including a structural spine described herein may be used as structural supports for protecting the vehicle as a whole or more particularly for protecting the battery packs of an Electric Vehicle (EV 10). [0074] Structural frame assemblies 20 generally comprise a frame cavity 22 with an inner frame wall 24 and an outer frame wall 26. These assemblies 20 may be part of a vehicle chassis frame 12 or as part of a body-in-while 14, as shown in Figs. 1 and 2. These may be formed of a variety of materials. The frame members may have certain members formed of one material and other frame members formed of a second material. The frame assemblies may be formed of polymeric materials (e.g., polyurethane, polyamide, polypropylene), metallic materials (e.g., aluminum, steel, magnesium), fibrous materials (glass fibers, carbon fibers, aramid fibers), or some combination of these materials. To the extent that the assemblies 20 (or the reinforcement insert assembly 30 or spine 50) utilize an adhesive, the adhesive may be an acrylate-based adhesive, an epoxy-based adhesive, polyurethane-based adhesive, polyimide-based adhesives, or some combination thereof. The adhesive may be a one or two component reactive adhesive. The adhesive may be in the form of a film or tape. The adhesive may be a hot melt adhesive. The adhesive may be a foaming adhesive. The adhesive may be activated (e.g., to cure, foam, adhere or the like) by a stimulus. The adhesive may activate as a result of combining two components.

[0075] It is contemplated that the function of the inserts/bulkheads is to preserve the cavity section of the vehicle body structure in an impact event while providing energy absorption to maximize protection of occupants and inboard components. The performance can be enhanced with adhesive positioned along the perimeter of the inserts/bulkheads joining the mating metal components to form a unified structure capable of higher reinforcement and energy absorption. There would be a minimum of 2 inserts/bulkheads and a maximum determined by their size and the length of the cavity to be reinforced. Size and spacing of the inserts/bulkheads could be determined through CAE analysis and physical testing.

[0076] Bulkheads: Typically, the width of each bulkhead would range from 15mm to 50mm. Each bulkhead could be an offset of the cavity to be reinforced but is not mandatory. The geometry of the bulkhead could include ribs and other features to increase its strength. The bulkheads can provide a continuous perimeter of adhesive to bond the entire perimeter of the cavity. The bulkhead has a sleeve feature/channel allowing for the spine to pass through. In one embodiment, adhesive in the sleeve feature can be used to bond the bulkhead to the spine. Materials contemplated could include polymers, such as Nylon (super tough, glass reinforced, unfilled), metals, such as cast aluminum or steel.

[0077]Typically, the width of each bulkhead would range from 50mm to 500mm. The insert could be an offset of the cavity to be reinforced but is not mandatory. Adhesive on the inserts could bond to the cavity section substrates. The geometry of the bulkhead could include ribs and other features to increase its strength. The ribs can be designed to avoid components in the cavity being reinforced. The sleeve feature for the spine can be created in die-pull without tooling action.

[0078] The function of the structural spine is to connect all the inserts/bulkheads to provide a single assembly for installation into the application. The spine carries and distributes load through the multiple inserts/bulkheads in the assembly to the vehicle structure.

[0079] The reinforcement insert assembly 30 with two or more inserts 40 including at least one structural spine 50 that ties the inserts 40 together is the focus of the present invention. It is contemplated that the inserts 40 function to provide at least a level of local reinforcement to the frame assembly 20. It is also contemplated that the spine 50 ties the inserts 40 together and provides at least a level of load transfer or sharing between at least adjoining inserts in the event of a crash event (e.g., side or potentially other crash events as shown in Figs. 7 and 8). It is contemplated that the assembly 30 includes at least two inserts 40 but can include a multitude of inserts. As shown in illustrative examples in Figs. 5 and 6, there can be 17 or more inserts 40 spaced apart from one another or as few as 4 inserts 40 that are immediately adjacent for each other. As also can be seen, each assembly 30 has at least 1 spine interfacing with each insert 40. Each of the respective components are described in further detail in the subsequent paragraphs.

[0080] It is contemplated that the reinforcement inserts/bulkheads 40 of the present invention are very similar to those already known in the art but include at least features are adapted to and that function to interface the spine 50. These features may include integral mechanical interfaces, adhesive interfaces, and other interfaces that require additional components (e.g., screws or clips or similar) or any combination thereof. It is contemplated in one preferred embodiment, that the spine 50 is disposed in an insert channel 42 that runs through a portion of the insert, for example as can be seen in Figs 3 and 4. It is also contemplated that there may also be an adhesive that bonds the spine 50 to the insert at or near the insert channel 42. There also may be a mechanical connection therebetween facilitated by screws or snaps or similar device (not shown). It is also contemplated that one or more of the inserts include features to allow one insert to have an alternative connection with one another (in addition to the spine 50 connection), for example as shown in Fig.9, where each insert has a snap feature - a male snap 44 and a female snap 46. It is also contemplated that at least a portion of the outer surface of the insert/bulkhead 40 be covered in an adhesive 48 that allows the component to be bonded to the wall of the cavity 22.

[0081] It is contemplated that positioning of the bulkheads 40 could be determined through CAE analysis and to avoid components in cavity 22. The inserts/bulkheads could be placed in pockets or in other locating features in an assembly fixture. The spine could then be passed through the sleeve features (channel 42) of the inserts/bulkheads 40 and positioned with locating features and clamps. The inserts/bulkheads could be fastened to the spine with adhesive or mechanical clip to maintain proper positioning as the assembly is transported and installed. In addition to the adhesive on the inserts/bulkheads which bond to the cavity substrates, adhesive could also be located at the spine interface to achieve further rigidity when activated and cured.

[0082] It is contemplated that the present invention includes at least one structural spine 50. The spine 50 functions to connect adjacent inserts 40 and may provide structural and energy absorption support for the reinforcement insert assembly 30 and may carries and distributes load through the multiple inserts/bulkheads in the assembly 30 to the vehicle structure. It is contemplated that the spine 50 may be constructed of many different materials such as a polymeric compound (e.g., pultrusion), a metallic composition (e.g., Aluminum extrusion or roll formed steel), or any combination thereof. The spine 50 may be ridged or flexible in nature. It may include one or more holes or locator features to locate or help affix the inserts 40 to the spine 50. The spine 50 may include an adhesive to aid in connection to the inserts 40. It may be constructed of various shapes that can be determined by the requirements of the assembly 30 to withstand various dynamic and static loads (see Figs. 7 and 8). In one preferred embodiment, as shown in Figs. 3A and 4, the spine 50 has a generally cross-shaped cross-section. It is further contemplated that other configurations may be desirable, such as but not limited to: C-channel (as seen in Fig.3B), round-tube, square-tube, W-shaped, T-shaped, S- shaped, and V-shaped. It is also contemplated that there will be more than one spine 50 as part of the assembly 20, but preferably if it there are - then the spines 50 overlap one another horizontally on at least one of the inserts 40.

[0083] The spine 50 or the inserts 40 may require that one or more of the components include a means that temporarily holds the components in place until the adhesive is located into the assembly to adhere the components together and also to prevent separation of the components from one another during introduction of the adhesive. This means may include a snap fit or friction fit. This means may include welding or ultrasonic welding. The means may include a mechanical fastening means including a rivet, a bolt, a screw, a tree fastener, a hook, a nail, an anchor, an insert, a retaining ring, a washer, a pin, or any combination thereof. The spine 50 or inserts 40 may include structures formed in the members during manufacture (e.g., openings, divots, cut-outs, holes, keyed structures or other structures for facilitating such fastening.

[0084] The adhesive material may be a two-part material that activates (e.g., cures, foams, or some combination thereof) when the two parts are combined. Activation may occur at room temperature.

[0085] The adhesive material may be an epoxy-based material such as those disclosed in U.S. Patent Nos. 5,884,960; 6,348,513; 6,368,438; 6,811 ,864; 7,125,461 ; 7,249,415; and U.S. Patent Publication No. 2004/0076831 , hereby incorporated by reference in their entirety for all purposes. The adhesive may include one or more phosphate ester-based components such as those disclosed in U.S. Patent No. 10,550,220 hereby incorporated by reference in its entirety for all purposes.

[0086] Unless stated otherwise, dimensions and geometries of the various structures depicted herein are not intended to be restrictive of the invention, and other dimensions or geometries are possible. Plural structural components can be provided by a single integrated structure. Alternatively, a single integrated structure might be divided into separate plural components. In addition, while a feature of the present invention may have been described in the context of only one of the illustrated embodiments, such feature may be combined with one or more other features of other embodiments, for any given application. It will also be appreciated from the above that the fabrication of the unique structures herein and the operation thereof also constitute methods in accordance with the present invention. [0087] The preferred embodiment of the present invention has been disclosed. A person of ordinary skill in the art would realize, however, that certain modifications would come within the teachings of this invention. Therefore, the following claims should be studied to determine the true scope and content of the invention.

[0088] The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the invention, its principles, and its practical application. Those skilled in the art may adapt and apply the invention in its numerous forms, as may be best suited to the requirements of a particular use. Accordingly, the specific embodiments of the present invention as set forth are not intended as being exhaustive or limiting of the invention. The scope of the invention should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. Other combinations are also possible as will be gleaned from the following claims, which are also hereby incorporated by reference into this written description.

Claims

CLAIMS What is claimed is:

1. An insert assembly comprising:

(i) a first insert member;

(ii) a second insert member arranged adjacent to the first insert member;

(iii) an adhesive, structural material, sealing material, tape, or some combination thereof, disposed on at least a portion of the first or second members, or both; and

(iv) at least one structural spine member arranged in direct contact and attached to the first insert member and to the second insert member creating the insert assembly.

2. The assembly of claim 1 , wherein the at least one structural spine member is comprised of a pultruded polymer with reinforcing fiber strands and configured as a single unitary component with a cross-shaped cross-section.

3. The assembly of claim 1 or claim 2, wherein the assembly includes a structural material, a sealing material, an adhesive, a tape, or some combination thereof along a portion of a periphery of one or more of the first insert member, the second insert member, or the at least one structural spine member.

4. The assembly of claim 2 or claim 3, wherein the at least one structural spine member is disposed in a channel of at least one of the first insert member and second insert member and wherein the channel has a complementary shape to the cross-shaped cross-section of the at least one structural spine.

5. The assembly of claim 4, wherein the channel, the at least one structural spine member, or both, includes an adhesive for bonding a wall of the structural spine and insert to one another.

6. The assembly of any of claims 1 through 5, including multiple spines located within the insert assembly.

7. The assembly of any of the preceding claims, wherein an impact load is distributed via the at least one structural spine member from the first insert member to the second insert member.

8. The assembly of any of the preceding claims, wherein a cross-section of the spine member has a curved shape, a T-shape, an M-shape, a W-shape, a V-shape, a U-shape, a circular shape, an oblong shape, a C-shape, and X-shape, an l-shape, or some combination thereof.

9. The assembly of any of the preceding claims, wherein the spine member has a length in the direction of a longitudinal axis of the assembly of at least 250 mm, at least 500 mm, or even at least 1000 mm.

10. The assembly of any of the preceding claims, wherein the spine member has a length in the direction of a longitudinal axis of the assembly of at least 250 mm, at least 500 mm, or even at least 1000 mm.

11 . The assembly of any of the preceding claims, wherein the first insert member, the second insert member, or both include a plurality of side walls and at least one side wall lies in direct planar contact with a vehicle cavity wall.

12. The assembly of any of the preceding claims, wherein the first insert member, the second insert member, or both include a plurality of side walls and a plurality of rib structures.

13. The assembly of claim 12, wherein at least one rib structure extends in a direction that is substantially perpendicular to at least one side wall.

14. The assembly of claim 12 or claim 13, wherein the plurality of rib structures have a rib height of at least about 10 mm, at least about 30 mm, or even at least about 50 mm.

15. The assembly of any of claims 12 though 14, wherein the plurality of rib structures have a rib width of at least about 5 mm, at least about 10 mm, or even at least about 20 mm.

16. The assembly of any of the preceding claims, wherein the first insert member, second insert member, and/or spine member includes a mechanical fastener.

17. The assembly of any of the preceding claims, wherein the first insert member, second insert member, and/or spine member includes a plurality of cell-like structures formed by side walls, ribs, or some combination thereof.

18. The assembly of any of the preceding claims, wherein the first insert member, second insert member, and/or spine member include one or more openings formed in a side wall, a rib, or some combination thereof.

19. The assembly of claim 18, wherein the one or openings receive a portion of a mechanical fastener.

20. The assembly of any of the preceding claims, wherein the spine member is substantially free of any direct contact with a vehicle cavity wall.

21. The assembly of claim 4, wherein the channel is formed by at least two rib structures.

22. The assembly of claim 4, wherein at least a portion of the channel is formed by a rib structure that splits into two rib structures with an opening therebetween that forms the channel.

23. The assembly of any of the preceding claims, including three or more insert members.

24. The assembly of any of the preceding claims, wherein the length of each insert member measured along the longitudinal axis of the spine member is less than 1000 mm, less than 500 mm, less than 100 mm, or even less than 20 mm.

25. The assembly of any of the preceding claims, wherein each insert member is the same shape and size.

26. The assembly of any of the preceding claims, wherein one or more insert member differs in shape and size from another insert member.

27. The assembly of any of the preceding claims, wherein the length of the spine member along the longitudinal axis of the assembly is longer than the combined length of all of the insert members.

28. The assembly of any of the preceding claims, wherein each insert member is the same shape and size.

29. The assembly of claim 4, wherein the channel receives only a portion of the spine member.

30. The assembly of claim 4, wherein the channel receives the entirety of the spine member.

31. The assembly of any of the preceding claims, wherein each insert member is substantially free of direct contact with any adjacent insert member.

32. The assembly of any of the preceding claims, wherein one or more insert members is in direct contact with one or more adjacent insert members.

33. The assembly of any of the preceding claims, wherein one or more insert members includes a plurality of rib structures and the rib structures have a top edge that is substantially co-planar with the top edge of one or more adjacent rib structures.

33. The assembly of any of the preceding claims, wherein one or more insert members includes a plurality of rib structures and the rib structures have a top edge that lies in a different plane than the top edge of one or more adjacent rib structures.

34. The assembly of any of the preceding claims, wherein one or more insert members includes at least two side walls or even at least three side walls.

35. The assembly of any of the preceding claims, wherein the insert members are formed of a polyamide-based material.

36. The assembly of any of the preceding claims, wherein the spine member is formed of a polyurethane-based material.

37. The assembly of any of the preceding claims, wherein the adhesive, structural material, sealing material, tape, or some combination thereof, comprises a material adapted to expand upon exposure to a stimulus.

38. The assembly of any of the preceding claims, wherein the assembly includes at least two different materials selected from adhesive, structural material, sealing material, tape, or some combination thereof,

39. The assembly of any of the preceding claims, wherein the adhesive, structural material, sealing material, tape, or some combination thereof, comprises a two-part material.

40. The assembly of any of the preceding claims, wherein the adhesive, structural material, sealing material, tape, or some combination thereof, comprises a two-part material including an A-side and a B-side, and wherein the B-side includes one or more phosphate esters.

41. The assembly of any of the preceding claims, including a structural material that is epoxy-based.

42. The assembly of claim 41 , wherein the structural material comprises polyvinyl butyral.

43. The assembly of claim 41 or claim 42, wherein the structural material has wherein the material has a strain to failure of greater than 2% and a modulus of at least 700 MPa as measured in accordance with ASTM D638 Type IV test method.

44. The assembly of any of the preceding claims, including a sealing material that is ethylene-based.

45. The assembly of any of the preceding claims, wherein the adhesive, structural material, sealing material, tape, or some combination thereof, has adhesive characteristics either in a green state (e.g., prior to any foaming and/or curing) or during foaming and/or curing).

46. The assembly of any of the preceding claims, including a two-part material that is injected into and/or around the assembly once the assembly is located in a desired location.

47. The assembly of any of the preceding claims, including an adhesive located in between the insert members and spine member.

48. The assembly of any of the preceding claims, including an adhesive located in between the insert members and spine member and a two-part material that is injected into and/or around the assembly once the assembly is located in a desired location.

49. The assembly of claim 48, wherein the adhesive is heat-activated to adhere and cure.

50. The assembly of any of the preceding claims, wherein the adhesive, structural material, sealing material, tape, or some combination thereof is adapted to foam, cure, and/or develop adhesive characteristics upon exposure to a stimulus selected from heat, moisture, or chemical activation.

51. A method comprising: pultruding an elongated spine member; molding one or more insert members to have a channel located therein; and locating the elongated spine member into the channel.

52. The method of claim 51 , including overmolding the one or more insert members onto the elongated spine member.

53. The method of claim 51 or 52, including locating an adhesive in between the elongated spine member and one or more insert members to adhere the one or more insert members to the spine member.

54. The method of any of claims 51 through 52, locating the elongated spine member and one or more insert members into a vehicle cavity.

55. The method of any of claims 51 through 54, including injecting a two-part material onto and/or around the elongated spine member and one or more inserts.