[001] The present invention relates generally to reinforcement of structures wherein -reinforcement devices are formed having bridge portions inserted in between segments of the reinforcement devices so thai the bridge portions facilitate simplified separation of the segments if necessary.

BACKGROUND OF THE !NVeCROtf:

[002] Structural reinforcement devices are frequentl formed from high strength materials in an effort to meet increasing crash performance requirements. As a result, scenarios where the reinforcement devices must be severed fsuch as vehicle crash) present a number of challenges given the High strength nature of the reinforcements., i addition, certain types of vehicles including hybrid and electric vehicles require certain precautions during vehicle crashes due to their electrical systems,

10031 thus, there remains a need for alternative devices that provide the requisite high strength reinforcing capability, while also being farmed to allow for easy severing through the reinforcement materials as may be necessary. There is a need for reinforcing inserts that can foe cut post-vehicle .crash,, but also provide sufficient reinforcement to protect vehicle occupants during crash, There is also a need for devices thai indicate where hybrid and/or electric vehicles ca be safely cut post-vehicle crash,

^' SUMMARY ^' OF THE ¾VE T50M

[00 ] The present invention meets one or more of the above needs by the improved devices and methods described herein. [00$] ^' In one aspect, the present inventio p rtains to a pillar for an automotive vehiele comprising: an elongated continuous outer layer of sheet meta and a plurality of high strength steel- reinforcing segments in spaced relationship to- each other to define gaps between the segments and being located beneath the outer !ayer of sheet metal. The pillar may further include an elongated structural reinforcement insert comprising a rigid bridge and a structural foam located on the rigid bridge and bonded to the reinforcing ^' segments, the insert ^' being disposed to brldgingly connect the reinforcing segments. The structure is defined so that it can be readil cut to extricate a vehicle passenger without the need to cu the high strength steel reinforcing segments, while still retaining sifucturafihtegrity of the pillar for resisting collapse in a crash event

f0O6] The pillar a described herein may also be formed such that the reinforcing segments and rigid bridge are connected by a connector. The rigid -bridge may include connector for bridging connection to one or more reinforcing segments prior to any expansion of the structural foam. The rigid bridge may include one or more metal tabs to which the reinforcing segments can be welded. The rigid bridge may be configured to receive one or more mechanical fasteners that connect the: rigid bridge with the reinforcing segments. The rigid bridge may be substantially free of any metallic material. The rigid bridge may include an enlarged cross-section in a gap formed in between two adjacent reinforcing segments. The structural foam may extend Into the gap and bond to the outer sheet metal. The rigid bridge may be formed of a polymeric material

[007] One or more of the reinforcing segments may be a metallic stamping, roll form, hydroform, casting, machined part or ^■ extrusion. At least a portion of each of the reinforcing segments has a minimal wail thickness of at least about 0,5mm. The rigid bridge may substantially entirely enclose at least a portion of one or more reinforcing segments. The rigid bridge portion substantially entirely encloses the entiret of one or more reinforcing segments, The _: rigid bridge may include one or more markings to Indicate where the rigid bridge should be severed. Adjacent reinforcing segments may be substantially free of any direct contact with on® another and are connected only via the rigid bridge. The pillar may be an A-psJiar, B-pil ar, or C-pillar of a motor vehicle and includes exactly two reinforcing segments and one rigid bridge. The pillar may be rocker panel and may include exactly two .rigid bridges. The ^' rigid bridge may be removably connected to one or more reinforcing portions for simplified replacement The structural foam may be free of any direct contact with the sheet metal post- expansion,

|008| The present teachings -further provide for an elongated polymeric rigid bridge comprising an enlarged central cross-section, a narrowed portion located at each of two ends of the enlarged cross section, a structural foam located o at least a portio of each of the enlarged cross section and narrowed portions and at least two fastening members, each located one of the narrowed portions:.

[OOiJ The teachings herein provide for the formation of cut zones within structural reinforcements to allow for easier severing of the reinforcements should any need to cut the reinforcements arise. The cut zones may be formed by inserts forming rigid bridge portions, the rigid bridges being formed of materials that are dissimilar from those forming adjacent reinforcing segments, The rigid bridges may be formed of polymeric materials that are more easily severed than the high strength materials.

BR E DESCRIPTION ^' OF THE D AWINGS

OOtO] Fig, 1 shows an illustrative cross-section of a vehicle pillar in accordanc with the present teachings.

[0011 ] Fig. 2 shows an illustrative side profile view of the exterior of a vehicle pillar and rocker panel i accordance with the present teachings,:

[0012] Fig, 3 shows a side profile v ew of the exterior of the vehicle pillar and rocke panel of Fig. 2 post-cutting.

[0013] Fig. 4 shows an illustrative side profile view of a. vehicle A-pi!iar, 8- m, C-pillar and rocker panel in ^' accordance with the present teachings... [0014] Fig.. 6 shows a side prof le view of the exterior of the vehicle pillars nd rocker panel of Fig, 4 post-cutting.

DETAILED OISCRIFOOH

0015] The explanations and illustration presented herein are intended to acquaint others skilled in the art with the teachings, its principles, and its practical application. Those skilled in the art may adapt and apply ffie teachings in its numerous forms, as may be best suited to the requirements of a particular use. Accordingly, the specific embodiments of the present teachings as set forth are not intended as being exhaustive or limiting of the teachings. The scope of the ^' teachings 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 application and publications* are incorporated b reference for all purposes. Other combinations are also possible as will fee gleaned from the following claims, which are also hereby incorporated by reference into this written description.

£001 §3 This application claims the benefit of the filing date of U.S. Provisional Application Serial Mo. 61/651 ,220, filed on fv!ay 24, 2012 _» the contents of which are incorporated by referenc herei for all purposes.

[0017] Th present teachings are directed to the formation of cut zones within structural reinforcements (e.g., reinforcing segments that are connected and/or integrally formed) to allow for easier severing of the reinforcements should any need to cut the reinforcements arise. The cut zones may be formed by materials that are lower in strength than adjacent material forming the reinforcements, ore specifically, a reinforcement that would generally be formed of a singular member _. , may Instead be formed by two reinforcing segrnents with a oid therebetween, That void may b filled with a part that connects the two reinforcing segments. The part for filling the voids may comprise an insert arid/or bridge portion formed of polymeric materials that provide sufficient strength in the cut zones but are more easily severed than the materials generally forming the structural reinforcements {e.g., metallic materials including; but: not limited to steel). Th bridge portions may further include a structural foam material located onto at least portion of the bridge which may expand after installation of the bridge. The bridge portions may be- connected with the reinforcing segments so that adjacent reinforcing segments are free of any direct contact with one another. Alternatively, at least a portion of a reinforcement may remain in the veld such that the bridge only encompasses a portion of the void and portio of reinforcement material remains in the void.

Q01S] In one specific example, pillars and rockers in automotive vehicles ar generally formed of high strength metallic materials that are difficult to cut. Each pillar or rocker may be formed of one consistent integrally formed metal sectio or ma be formed of multiple metal sections welded or fastened to one another, Based upon the cutting difficulty, the current teachings are directed toward the integration of rigid bridges In one or more locations along a pillar or rocker. These bridges may be inserted at a location where two or more reinforcing segments would have been directly welded or connected to one another. Alternatively, a reinforcing segment may be cut prior to Installation into a vehicle frame and the bridge inserted between the two remaining reinforcing segments thereby connecting the reinforcing segments. The connected segments may then be installed into a vehicle frame.

f0O†¾ Each bridge may be connected to one or more reinforcing segments. The bridge may be located between two or more adjacent reinforcing segments and may thus prevent direct contact betwee the two or more reinforcing segments. This lack of direct -contact may also result in a reduction of corrosion over time, given that the metallic materials ar no longer in direct contact but are instead connected via a polymeric bridge. In order to connect the bridge to one or more reinforcing segments, each bridge may include one or more fasteners or alternative means: for connecting the bridge to one or more reinforcing segments.

[0020] The fastener may be a threaded screw fastener ^" or a tree-fastener. The fastener may also be provided in a variety of shapes and in a variety of configurations so Song as It: can secure the bridge to one or more reinforcing segments. Examples: of- additional suitable -fasteners- Include mechanical fasteners, clips, tabs, press-fits, snap-fifes screws, hooks, combinations thereof or the like. Furthermore, if Is contemplated that the one or more fasteners may be formed integral of a singular material with the material of the bridge or the reinforcing segment or may be formed, of a different material and may be removably attached to the bridge and/or reinforcing, segment, The fastener may be provided as a magnetic material or an adhesive - ^' material that can attach (e.g., adhere or magnetically secure) the bridge to one or more reinforcing segments. The structural foam may have adhesive properties so that the foam assists in adhering the bridge to one or more of the reinforcing segments and or the sheet metal surrounding the reinforcing segments,

[0011] The fastening means may be formed as a weld tab for welding the bridge to one o more reinforcing segments. The weld tab may be formed of a material that is dissimilar to that forming the bridge and may be connected to the bridg via an adhesive or fastener or ma be molded into the bridge. The weld fab may be formed of a metallic material for welding directly to one or more reinfo ing segments.

f¾022] In one preferred embodiment, the bridge ma be made of a nylon or other polymeric material. The bridge may be injection molded, extruded, die cast, or machined comprising materials such as polysulfone, polyamldes (e.g.), nylon, PBi, o PEL The reinforcing segments may be selected from materials consisting of boron steel, aluminum, extruded aluminum, aluminum foam, magnesium, magnesium alloys, molded magnesium alloys, titanium, titanium alloys, molded titanium alloys, pofyureihanes, polyurethane composites, low density solid fillers, and formed SMC and ^' BMC.

|0C 23f At least a portion of the bridge ma be contacted with one or more structural foam materials or adhesives which may be expandable materials, in a preferred embodiment, the expandable material is an epoxy based material such as those disclosed in U.S. Patent Nos. 5,884,960; 8,348,51$; 8,388,438; 6,811 ,864; 7,125,461; 7,249,415;. and published U.S. Application No. 20040078831 , hereby incorporated by reference.. The structural foam matenal may be located onto the bridge prior to inserting ^' the bridge into a. void between two o more segments. The structural foam may h located on one o more segments prior to insertion of the bridge prior to insertion of the bridge between adjacent segments. Th structural foam may expand to contact any adjacent surface which may include one or more of the segments and/or any surface along the exterior of a cavity which receives the bridge and segments (which ma be a sheet . ^' metal layer).

[00241 On or more of the reinforcing segments may be insert-molded within the bridge portion such that a reinforcing segment is inserted into a location and ^' molten material of the bridge portion is applied ove and around the second reinforcing portion, in another preferred embodiment, one or more reinforcing segments may be oo-exfruded with the bridge portion material and or the structural foam material The reinforcing segments ma also be attached to the bridge portion via a fastening means or adhesive, such fasteners or adhesive being applied to the bridg (o even applied to a reinforcing segment) via any of the methods described above.. The structural foam material may also be applied to one or more of the bridge and/or reinforcing segments via any of the methods described above,

[0 1211] Adjacent reinforcing segments ma be formed of different materials. More specifically, adjacent reinforcing segments may be formed of different metallic- materials. Thus, th bridge ma connect two different reinforcing segments where a first reinforcing segment is formed of a higher strength material and a second reinforcing segment is formed of a lower strength material The materia! of the second reinforcing segment may be selected so that the tensile strength and modulus of the second reinforcing segment i lower than that of the first reinforcing portion. The tensile strength of the first reinforcing segment material may be at least about 1 ,2 times the tensile strength of the second reinforcing segment material. More preferably, the tensile strength of the first reinforcing ^' segment material is at least about 2 times that of the second reinforcing segment material, or even S times that of the second reinforcing segment material As shown for example in Fig, 1 , a vehicle pillar 10 Includes an insert 11 comprising a rigid bridge 12.. The rigid bridge is connected via fasteners 14 to a first reinforcing segment 18 and a second reinforcing segment 18, The rigid bridge includes a layer of structural foam 20 located onto at least a portion of the bridge. The foam Is shown post-expansion. A layer of sheet metal 21 lies adjacent eac reinforcing segment so that the foam 20 expands to contact the sheet metal.

[0027] . 2 shows an exemplary vehicle pillar 10 and vehicle rocker 22. The .exterior of the pillar and rocker are shown. The pillar includes a first reinforcing segment i 8 and a second reinforcing segment 18 (both .located beneath a. sheet metal layer 21), A rigid bridge 12 (shown In dotted lines beneath the sheet metal layer 2:1} is inserted In between the first and second reinforcing segments. The vehicle rocker 22 includes a first reinforcing segment 18, a second reinforcing segment 18. and a tfilrd reinforcing segment 24 (boated beneath the sheet metal layer 21). The rocker also includes first rigid bridge 12 and a second rigid bridge 28 (shown, in dotted lines beneath the sheet metal layer 21),

|0O28| Fig. 3 shows the vehicle pillar 10 and rocker 22 of Fig. 2 post severing, The first and second reinforcing segments 18, 1$ -and ^' he rigid bridge 12 of the pilla are connected prior to severing, but the rigid bridge 1 is cut during the severing process so that the first and second reinforcing segments are no longer connected and the bridge is out into at least a first bridge portion 30 and a second bridge portion 32, The bridge is located so that in the event that the pillar mus be severed, the bridge 12 is cut as opposed to the first or second reinforcing segments 18, 8, The rocker Includes a first and second rigid bridge 12, 26 that are both shown as cut,, thereby disconnecting the first reinforcing segment 18 and second reinforcing segment 18, and also the second reinforcement segment 18 and third reinforcement segment 24,

|d§29] Fig, 4 shows a vehicle A ^» pii!ar 10a, B-piliar 10b, C-pillar 10c and rocker 22 of a vehicle prior to severing. The A-piilar, B-pillar an C-pillar each share a first reinforeing segment 16 and each includes respective second reinforcing segment I 8a~c. Each of the A-piliar, B-pillar and Opiilar also include a rigid bridge 12a-c. The rocker 22 includes a fi st, second and third reinforcing, segment 16, 18, 24 and a. first and second bridge 12, 28...

OSH] F1g> 5 the vehicle pillars 10a, 1 ^' Q.b, 10o and rocker 22 of Fig, 4 post severing. Th first reinforcing segment 18 and each second reinforcing segment of each pillar 18a, 18b and 18c are connected via respective - bridges. 12a, 12b and 12c- prior to severing. The rigid bridges 12a, 12b, 12c are shown as cut during the severing process so that the first and second reinforcing segments are no longer connected and each bridge is cut Into at least a f irst bridge portion 30a- G and a second bridge portion 32a-o. The bridges 12a, 12b _* 12c are located so that in the even! that the pillar must be severed, one or more of the bridge are cut as opposed to the first or second reinforcing segments 16, 8a~o, The rocker includes a first and second rigid bridge 12, 28 that are both shown as cut, thereby disconnecting the first reinforcing segment 1f and: second reinforcing segment 18, and also the second reinforcement segment 18 and third relnf o rcemenf segmen 24.

'0031 j While the examples show in the drawings ar directed toward vehicle pillar and rocker embodiments, it should be .recognized that the bridge inserts described herein may be utilized in any location where reinforcement is desired ahd or connection between adjacent parts is required, The bridges may be formed such that each end connects to one of two or more adjacent segments. The bridges may engage one or more segments in a friction fit arrangement The bridges may have any shape suitable for connecting two parts or segments, whether the parts are co-planar or located in differing planes. The bridges may located substantially vvithin an interior cavity of one or more adjacent segments such that only a small portion of the bridge is visible between the two segments. The bridge may merely provide additional support for a part havin a thin cross- section along part of its length,, such that the bridge is not connecting to separate segments but rather supports a singular segment.

p¾32] Th shape of the bridge is generally dictated by the shape and arrangement of the segments which are connected by the bridge. The bridge may be an elongated insert, a generally square or rounded insert* or any insert capable of connecting two or more parts (e,g<, segments). The cross-section shape of the bridge may be variable so that thai at least a portion of the bridge extends outward to contact an exterior layer of a cavity along any portion of the bridge not encompassed within a .segme t (e.g., any portion of the bridge where a segment is not located).

Unless stated otherwise, dimensions and geometries of the various structures depsoted 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 singl integrated structure. .Alternatively, a single integrated structure might he divided info separate plural components. In addition, while feature of the present invention may have been described in the context of only one of the illustrated embodiments, such feature mav 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,

P034] The preferred embodiment of the present invention has been disclosed, A person of ordinary skill In the art would realise however, that certain modifications would come within the teachings of this invention. Therefore, the following claims should be studied to determine the true scop and content of the invention.

[0035] 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 feeing exhaustive o 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 su ' 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.