MXPA00007607A - Three dimensional composite joint reinforcement for an automotive vehicle - Google Patents

Abstract

The joint reinforcement member (30) for a hollow structure of an automobile vehicle (13) has a carrier portion (22) with an outer surface. The carrier portion has a base portion (30) with a first extension having a first longitudinal axis and a second extension having a second longitudinal axis. The first longitudinal axis and second longitudinal axis correspond to the hollow structure. A thermally expandable adhesive layer (38) is disposed on the outer surface of the carrier portion and substantially covers the outer surface. A method for forming the joint member includes providing a carrier having a plurality of extensions extending from a base portion that correspond to the hollow structure, applying a layer of thermally expandable adhesive materials applied to the carrier portion. The carrier portion is heated to activate the adhesive layer. The adhesive layer is cooled so that the adhesive is bonded to the structural member.

Description

"BOARD REINFORCEMENT COM_PUESTO TRIDIMENSIONAL FOR AN AUTOMOTIVE VEHICLE" TECHNICAL FIELD The present invention relates generally to a reinforcement of hollow structural members and, more specifically, to a reinforcement of hollow structures of automotive vehicles which are generally inaccessible after being assembled.

BACKGROUND OF THE INVENTION Impact or impact resistance, fuel economy standards and structural rigidity are fundamental concerns in automotive structural design. Fuel economy regulations prescribe the use of lighter materials. This is usually interpreted as reducing the thickness of materials or using lighter weight material. Shock resistance prescribes the use of thicker materials at least in localized areas. Structural rigidity also typically requires an increase in material.

The use of composite materials that are generally stronger and lighter than their metallic duplicates has increased over the years. The present inventor has presented a novel approach to a partly structural reinforcement through localized reinforcement of critical regions using thermally expandable resins filled with microspheres, such as: a composite door beam having a resin-based core occupying a third part of the perforation of the metal tube; a hollow laminated beam characterized by high stiffness-to-mass ratio and having an outer portion that is separated from the inner tube by a thin layer of structural foam; a "W" shaped carrier insert reinforcement carrying a foamed body to be used to reinforce a hollow beam; a bulky head using a thermally expandable foam to provide localized reinforcement of a rail for the attachment of a motor stand or the like. Automotive vehicle joints are the weakest part of the structure. By providing rigidity to the joint, the total rigidity of the vehicle's running characteristics is improved. In the formation of the automotive vehicle body, several structural / body panel members are welded or bonded together. The joints are typically hollow by their nature. The Hollow structure allows the flow of an E layer through the structural members to increase the corrosion resistance. Various techniques have been used by automotive manufacturers to increase the rigidity of vehicle joints. Typically, the solutions have involved greatly increasing the volume, size and / or complexity of the joints to thereby increase rigidity. By increasing the volume of the joints, a precious packing space has been reduced. Also, the weight of the structure due to its volume has been increased.

COMPENDIUM OF THE INVENTION An object of the invention is, therefore, to reinforce a gasket of an automotive vehicle without having to increase the amount of sheet material required in the gasket. In one aspect, the present invention provides a carrier portion having an external surface. The outer surface has a plurality of extensions that conform to the joint where the joint reinforcement is to be placed. An adhesive layer is placed on the outer surface of the carrier portion. The outer surface is essentially covered by the adhesive layer. The layer adhesive is formed of a thermally expandable resin material. In another aspect, the invention provides a method for forming a reinforcing member. The method comprises the steps of providing a carrier portion; apply a layer of adhesive material to the carrier portion; heating the carrier portion and the adhesive portion; and ligating the adhesive portion to the structural member. In still another aspect, the present invention provides a method for forming an automotive body having at least two body members. The assembly of the body members defines between them a hollow space. The method includes the steps of forming a reinforcement member by applying a layer of adhesive material to a carrier portion; inserting the reinforcing member into the hollow space; and heating the body members and the carrier portion with the adhesive layer so that the adhesive material is bonded to the body members. An advantage of the present invention is that a reduced packing space for the body members can be provided. This is partly due to the fact that the lower gauge sheet metal can be used in all body members since the structural joints have been reinforced. This results in a desirable total weight reduction of the automotive vehicle.

BRIEF DESCRIPTION OF THE DRAWINGS Other features and advantages of the invention will become apparent from the detailed description that should be read in conjunction with the drawings in which: Figure 1 is a perspective, recessed view of an automotive vehicle having a structural reinforcing member; Figures 2a and 2b are perspective views of two portions of a carrier member; Figure 3 is a perspective view of a carrier wrapped with an adhesive layer; Figure 4 is a plan view of a sheet of adhesive material to be applied to a potter; Figure 5 is a cross-sectional view of the carrier within a mold; Figure 6 is a cross-sectional view of a reinforcement member in a hollow structure of an automotive vehicle; and Figure 7 is an alternative cross-sectional view of a reinforcing member having an interior of foam in a hollow structure of an automotive vehicle.

DETAILED DESCRIPTION OF THE PREFERRED MODALITY In the following figures, equal reference numbers will be used to represent the same components. The figures illustrate a carrier member having a specific shape. Other shapes and sizes for joint reinforcement, however, would be apparent to those skilled in the art based on the teachings herein. Referring now to Figure 1, there is shown an automotive vehicle 10 having a gasket 12. The gasket 12 is a hollow structure 13 defined by a quarter back internal panel 14, an external quarter back panel 16, a panel of inner door 18 and an outer door panel 20. A reinforcing member 22 is inserted into the hollow structure 13 to reinforce the gasket 12. Although reinforcing member 22 is shown illustrated within a specific gasket, the present invention has application to many joints of an automotive vehicle. As shown, the reinforcing member extends between the roof 24 and the "D" shaped pillar 26. The reinforcing member 22 is particularly suitable to reinforce the area where the hollow channels intersect 28. However, a modified reinforcing member 22 may also be appropriate to reinforce the intersection of two channels. The reinforcing member 22 has a body portion 30 and three extension portions 32. Each extension portion 32 has a longitudinal axis 34. The longitudinal axes 34 preferably coincide with the elongated axis of each of the channels 28. That is , the reinforcing members 22 can be constructed so that the longitudinal axes 34 are at various angles with respect to each other. The longitudinal axes 34 may be perpendicular to one another to coincide with the channels 28 to correspond to the different angles of an automotive vehicle design. The length of the extension portions 32 from the body portions 30 is a function of the amount of gasket 12 to be reinforced. Several distances within the channels 28 may be reinforced, depending on the structure of the body where the reinforcing member 22 is applied. In most applications, the extension portions 32 will extend to several centimeters from the body portion 30. As shown, the extension portions 32 have a generally square cross section. Without However, it is preferred that the extension portions 32 are configured in a manner similar to that of the channels 28. In this way, a better fit between the reinforcing member and the channels 28 can be achieved. Referring now to Figures 2A, 2B and 3, the reinforcing member 22 is preferably formed of a carrier 36 wrapped by an adhesive layer 38. The carrier 36 is preferably formed of a thin material capable of holding the adhesive layer 38. The amount is carrier that is provided by the carrier. carrier 36 is sufficient so that reinforcement member 22 can be handled and placed in the hollow structure of the automotive vehicle, during manufacturing without deforming. The carrier 36, for example, can be formed of a metallic material such as aluminum foil, a steel foil or a thin foil of aluminum. Appropriate thicknesses of this material can be, for example, .172 to .368 millimeters thick, 0.147 to .613 millimeters thick and .049 to 0.147 millimeters thick respectively. Other suitable materials to be used as a carrier are nylon filled with injected molded glass, from 1.52 to 6.13 millimeters thick, plastic blow molded or rotationally molded at a high temperature of 1.47 to 6.13 millimeters thick (abs or polystyrene) or cement foam molded by rotation or cast from 6.13 to 12.25 millimeters of thickness. Of course, the different thicknesses may vary, depending on the specific circumstances. Various methods can be used to form the carrier 36 in the carrier material. As illustrated in Figures 2A and 2B, two pieces of aluminum or steel can be punched to form two halves 40 and 42 of the carrier 36. The halves 40 and 42 can then be welded or joined together to form the carrier 36. As shown, the half 40 has ends 44 along each extension portion 32. In the preferred embodiment, however, the carrier 36 either does not have the ends 44 or has holes within the ends 44 to allow the passage of the E coating during Manufacturing to increase protection against corrosion. The addition of the ends 44, however, further increases the strength of the carrier 36. The carrier 36 can also be formed by placing a foil reinforced sheet through a three-dimensional foam core. The carrier 36 can also be formed by blow molding, injection molding, or molding the foam cement around a Styrofoa core, or by using an "aluminum can" or helmet as the internal carrier with processes based on the techniques for form cans for aluminum drinks. The carrier 36 can also be formed by hydroforming a metal in a three-dimensional configuration.

After or during the formation of the carrier 36, metal extensions such as pins 46 or metal tabs can be added to the carrier 36. The pins 46 are aligned with the holes in or near the seals 12. The number of pins 46 may vary with each application. The pins place the reinforcing member 22 within the channels 28 during the assembly of the vehicle. The channels 28 may have holes therethrough which align with the pins 46. The polymer used to form the adhesive layer 22 is a resin-based material that is thermally expandable. A number of resin-based compositions can be used to form the adhesive layer 38 in the present invention. Preferred compositions impart excellent strength and stiffness characteristics while being added only marginally to the weight. With specific reference now to the adhesive layer composition 38, the density of the material should preferably be from about 320 grams per cubic centimeter to about 800 grams per cubic centimeter to minimize weight. The melting temperature, the temperature of thermal distortion and the temperature at which the chemical disintegration occurs can be sufficiently high such that the adhesive layer 38 maintains its structure at high temperatures which typically found in paint ovens or other processing of the whole vehicle. Therefore, the adhesive layer 38 must be able to withstand temperatures in excess of 160 ° C, and preferably 177 ° C for short periods of time. Also, the adhesive layer 38 must be capable of withstanding in final service heats of about 32 ° C to 93 ° C for extended periods of time without exhibiting considerable distortion induced by heat or degradation. In more detail, in a particularly preferred embodiment, the thermally expanded structural foam of the adhesive layer 38 includes a synthetic resin, a cell-forming agent and a filler or filler. A synthetic resin comprises from about 40 percent to about 80 percent by weight, preferably from about 45 percent to about 75 percent by weight, and most preferably from about 50 percent to about 70 percent by weight of the adhesive layer 38. Most preferably, a portion of the resin includes a flexible epoxy. As used herein, the term "cell-forming agent" generally refers to the agents that produce bubbles, pores or cavities in the adhesive layer 38. That is, the adhesive layer 38 has a cellular structure, having numerous cells placed through its mass. The Cellular structure provides a low density, high strength material, which provides a sturdy yet lightweight structure. Cell forming agents that are compatible with the present invention include reinforcing "hollow" microbeads or microbubbles that can be formed from either glass or plastic. The glass microspheres are particularly preferred. Also, the cell forming agent can comprise a blowing agent which can be either a chemical blowing agent or a physical blowing agent. Even when the cell forming agent comprises microspheres or macrospheres, it constitutes from about 10 percent to 50 percent by weight, preferably from about 15 percent to 40 percent by weight and most preferably, from 20 percent to about 6 percent by weight. 40 weight percent of the material forming the adhesive layer 22. When the cell forming agent comprises a blowing agent, it constitutes from about 5 percent to about 5.0 percent by weight, preferably from about 1 percent to about 4.0 percent by weight, and most preferably from about 1 percent to about 3 percent by weight of the adhesive layer 38. Suitable fillers include glass or plastic microspheres, fuming silica, cationic carbonate, glass fiber milled, and glass crushed A thixotropic filler material is particularly preferred. Other materials may be appropriate. The filler material comprises from about 1 percent to about 15 percent by weight, preferably from about 2 percent to about 10 percent by weight, and especially preferably from about 3 percent to about 8 percent by weight of the adhesive layer 38. Preferred synthetic resins for use in the present invention include thermosetting materials such as epoxy resins, phenol ester resins, thermosetting polyester resins, and urethane resins. It is not intended that the scope of the present invention be limited by the molecular weight of the resin and the appropriate weights will be understood by those skilled in the art based on the present disclosure. When the resin component of the liquid packing material is a thermosetting resin, it may also be included to improve the cure rate in various accelerators such as imidazoles and curing agents, preferably dicyandiamide. A functional amount of the accelerator is typically from about .5 percent to about 2.0 percent of the weight of the resin with the corresponding reduction in one of the three components, resin, cell forming agent or filling material. Similarly, the amount of the curing agent is typically from about 1 percent to about 8 percent of the weight of the resin with a corresponding reduction in one of the three components, the resin, the cell-forming agent or the coating material. filling. The effective amounts of processing aids, stabilizers, colorants, ultraviolet light absorbing agents and the like can also be included in the layer. Thermoplastics may also be appropriate. In the following table, a preferred embodiment is indicated for the adhesive layer 38. It has been found that this formulation provides a material that is fully expanded and cured at a temperature of about 160 ° C, and provides excellent structural properties. All percentages in the present exposure are percentage by weight unless specifically designated otherwise.

Ingredients Scale Percentage Weight% Preferred EPON 828 (epoxy resin) 30-40 36.96 DER 331 (flexible epoxy resin) 10-20 15.06 AMICURE CGNA (curing agent) 3.5-4.6 4.12 AMICURE VR (accelerator) .4-1.2 .80 TS720 (thixotropic filler) .5-1.5 1.1 CELOGEN AZ 199 (blowing agent for azodicarbonamide) .7-1 1.21 B38 MICROS (glass microspheres) 30.0-45.0 37.16 CALCIUM CARBONATE WINNOFIL (CaC0 filler material) or CARBON NEGRO .1-1.1 .6 NIPOL 1312 (liquid rubber) 2.0-4.0 3.01 Dyes and other additives such as phthalocyanine blue and KR55 may also be included. The adhesive layer 38 in most applications is a layer that extends around or essentially around the entire outer surface of the carrier 36. It is preferred that the adhesive layer 38 be of relatively uniform thickness, eg, from about 2 to about 6 millimeters, in the unexpanded state.

Referring now to Figure 4, the adhesive layer 38 can be prepared by matrix cutting a sheet 48 of resin to the required geometry. The cut portion with die 50 is then wound around the three-dimensional carrier 36. Alternatively, other forms of coating carrier 36 may be used. For example, the adhesive layer 38 may be applied by spraying or compression molding. Referring now to Figure 5, another method for applying the adhesive layer 38 to the carrier 36 is through the use of a mold 52. The carrier 36 is placed inside a mold 52. A space or gap 54 between the mold 52 and the carrier 36 is preferably uniform and sized to the desired thickness of adhesive layer 38. An orifice 56 is provided through mold 52 so that the material of the melted adhesive layer can be injected into the space or interval 54 to encircle the carrier 36. It is preferred that the mold 52 be cooled and polished to facilitate the release of the piece. This can be accomplished in several ways such as by running cooling fluids through the mold body 52. By cooling the mold 52, separation of the adhesive layer 38 from the mold 52 is simplified.

A cross-sectional view of a reinforcing member 22 formed in accordance with Figures 3, 4 or 5, as shown. The adhesive layer 38 is uniformly applied around the carrier 36. The carrier 36 is preferably hollow and generally conforms to the channel 28. The adhesive layer 38 has the characteristics that when the vehicle is subjected to baking for painting, the layer adhesive 38 expands and binds to channels 28. In this way, after adhesive layer 38 is cooled, adhesive layer 38 is bonded to channels 28 to reinforce joint 12. Because the joints of the vehicle are structurally reinforced, the stiffness and running characteristics of the vehicle are improved, which allows the reduction in weight by reducing the caliber or thickness of the metal that is provided to form the panels of the vehicle body. Referring now to Figure 7, a cross-sectional view of an alternative method for forming the reinforcing member 22 is shown. Instead of having a hollow shell as in Figure 6, the carrier 36 is formed having a foam core 58. A thin sheet or metallic layer forms the carrier 36. For example, a thin layer of aluminum may be wrapped around the foam core 58. By using a foam core 58, the adhesive layer 38 may be applied to any of the ways, specified above. The foam core 58 is preferably formed of a thermally activated or fugitive material. That is, when the foam core is subjected to heat, the core of the form disintegrates to leave a hollow carrier 36. The preferred heat for the foam core 58 to disintegrate is at a maximum temperature at which the vehicle is undergoes during the painting baking operation. By using a foam core 58, a slightly stiffer reinforcement member 22 is obtained and therefore the reinforcing member 22 can be easier to handle during vehicle assembly, especially when using thinner carriers. In the operation, the reinforcing members 22 as described above would tend to be supplied to the automotive assembly plants. The reinforcing members may be manufactured in accordance with any of the methods indicated above. During the assembly of the vehicle body and before welding or the different panels of the vehicle, reinforcement members would be placed in several joints of the vehicle. Preferably, any of the gaskets and adhesive layer 38 are aligned with any of the seams in the vehicle body. After the members of the reinforcement 22 are inserted into the joints, the body panels are joined together.

Commonly, the body of the vehicle once it has been welded together is subjected to coating E. During the coating E, the body is immersed in a coating puddle E. The coating E flows through the hollow reinforcement member 22 to coat the body. body including the interior of the channels 28. Subsequently, the paint is then applied to the body panels. After the paint is applied to the body panels, the paint is baked. During this baking process, the temperature of the body panels rises considerably. Commonly, body temperatures exceed 163 ° C. The temperature inside the channels 28 also rises to that temperature. This temperature then activates the adhesive layer 38 so that it expands and is bonded to the interior of the body panels within the channels 28. When cooled, the reinforcing member 22 is bonded to the body panels and the joint is then reinforces. Although the best way to carry out the present invention has been described in detail, those familiar with the technique to which this invention relates will recognize various alternative designs and embodiments for practicing the invention as defined by the following claims. .

Claims (34)

CLAIMS:

1. A joint reinforcement member for a hollow structure of an automotive vehicle comprising: a carrier portion having an outer surface, the carrier portion having a base portion having a first extension having a first longitudinal axis extending from the same and having a second extension having a second longitudinal axis extending therefrom, the first longitudinal axis and the second longitudinal axis correspond to the aforementioned hollow structure; and a thermally expandable adhesive layer placed on the outer surface and essentially covering the outer surface.

The joint reinforcement member according to claim 1, wherein the first longitudinal axis is perpendicular to the second longitudinal axis.

A joint reinforcement member according to claim 1, wherein the portion of the carrier comprises a third extension extending from the base portion, the third extension having a third longitudinal axis.

4. A joint reinforcement member according to claim 3, wherein the third axis longitudinal is essentially perpendicular to the first and second longitudinal axes.

5. A gasket reinforcement member according to claim 1, wherein the portion of the carrier is hollow.

6. A gasket reinforcement member according to claim 1, wherein the outer surface has a metal layer.

7. A gasket reinforcement member according to claim 1, wherein the carrier has metal extensions extending therefrom.

8. A gasket reinforcement member according to claim 1, wherein the carrier has through holes.

9. A joint reinforcement member for a hollow structure of an automotive vehicle comprising: a portion of the carrier having an external surface, the portion of the carrier having a base portion having a first extension having a first longitudinal axis that it extends from it and has a second extension having a second longitudinal axis extending therefrom; a thermally expandable adhesive layer placed on the outer surface and essentially covering the outer surface; and where the carrier portion comprises two metal channels punched together coupled.

10. A joint reinforcement member for a hollow structure of an automotive vehicle comprising: a carrier portion having an external surface, - the carrier portion having a base portion having a first extension having a first longitudinal axis that it extends therefrom and has a second extension having a second longitudinal axis extending therefrom; a thermally expandable adhesive layer placed on the outer surface and essentially covering the outer surface, and wherein the carrier portion comprises a foam member coated with a thin sheet, the thin sheet forming the outer surface.

11. A gasket reinforcement member according to claim 10, wherein the foam member is thermally activated.

12. A joint reinforcement member for a hollow structure of an automotive vehicle comprising: a carrier portion having an external surface, the carrier portion having a base portion having a first extension having a first longitudinal axis extending from it and that has a second extension having a second longitudinal axis extending therefrom; a thermally expandable adhesive layer placed on the outer surface and essentially covering the outer surface; and wherein the adhesive layer comprises in percent by weight: synthetic resin between about 40% and about 80% a filler material between about 1% and about 15% a blowing agent between about 5% chemical and about 5% 13.

A method for forming a reinforcement member for placement within a hollow structure member of an automotive vehicle comprising: providing a carrier portion having a plurality of extensions extending from a base portion corresponding to the hollow structure member. apply a layer of the thermally expandable adhesive material to the carrier portion; heating the carrier portion and the adhesive layer; activate the adhesive layer; ligating the adhesive layer to the structure member; Y cooling the structure member and the adhesive layer, and further comprising the step of cutting the adhesive layer of a sheet of adhesive material.

A method for forming a reinforcing member according to claim 13, further comprising the step of cutting the adhesive layer from a sheet of adhesive material.

A method for forming a reinforcement member for placement within a hollow structure member of an automotive vehicle comprising: providing a carrier portion having a plurality of extensions extending from a base portion corresponding to the structure member hole; applying a layer of thermally expandable adhesive material to the carrier portion; heating the carrier portion and the adhesive layer; activate the adhesive layer; ligating the adhesive layer to the structure member; and cooling the structure member and the adhesive layer; wherein the step of applying the adhesive layer further comprises the sub-steps of placing the carrier portion in a mold; inject the adhesive layer between carrier portion and the mold; and, remove the carrier portion having an adhesive layer from the mold.

16. A method for foaming a reinforcing member according to claim 15, further comprising the step of cooling the mold.

17. A method for forming an automotive body having at least two elongated hollow body members, the assembly of the body members defining a hollow space therebetween comprising: inserting a reinforcing member into the hollow space, the member reinforcement has a carrier portion having an external surface and a base portion having a first extension having a first longitudinal axis extending therefrom and having a second extension having a second longitudinal axis extending from the same, the external surface of the carrier has a thermally expandable adhesive layer placed thereon; aligning the first extension with one of the hollow body members; aligning the second extension with the other of the hollow body members; heating the body members, the carrier portion and the adhesive layer; ligating the adhesive material within the hollow body members; and cooling the structural member and the adhesive layer; and further comprises the steps of forming the adhesive layer by cutting the adhesive layer of a sheet of the adhesive material.

18. A method for forming an automotive body according to claim 17, further comprising the steps of forming the adhesive layer by cutting the adhesive layer from a sheet of adhesive material.

19. A method for forming an automotive body 17 further comprising the step of applying the adhesive layer to the carrier.

20. A method for forming an automotive body 17, wherein the step of applying the adhesive layer to the carrier comprises the sub-steps of placing the carrier portion in a mold; injecting the adhesive layer between the carrier portion and the mold; and, remove the carrier portion of the adhesive layer from the mold.

21. A joint reinforcement member for use to reinforce a hollow structure of an automotive vehicle comprising a carrier portion having an outer surface, the carrier portion having a base portion, a first extension secured with and that extending away from the base portion, a second portion secured with and extending away from the base portion, the base portion connects the first extension with the second extension to form a continuous integral external surface of the first extension with the second extension, each of the first extension and the second extension are longer than the base portion, each of the first extension and the second extension have a longitudinal axis, the longitudinal axis of the first extension being non-collinear with the axis longitudinal of the second extension, and the longitudinal axis of the first extension and the longitudinal axis of the second extension intersecting in the base portion, and a thermally expandable structural foam bonded to the external surface and essentially covering the outer surface.

A joint reinforcement member according to claim 3 wherein the base portion connects the third extension with each of the first extension and the second extension to form a continuous integral external surface of the third extension with each of the first extension and the second extension.

23. A board reinforcing member according to claim 22, wherein the base portion and each of the extensions are tubular in shape.

24. A gasket reinforcement member according to claim 21, wherein the base portion and each of the extensions are tubular in shape.

25. A gasket reinforcement member according to claim 24, wherein the carrier is filled with core foam.

26. A gasket reinforcement member according to claim 24, wherein the carrier is hollow and empty.

27. A board-reinforcing member according to claim 23, wherein the carrier is filled with a core foam.

28. A joint reinforcement member according to claim 23, wherein the carrier is hollow and empty.

29. A gasket reinforcement member according to claim 12 wherein the adhesive layer further comprises from about 10 percent to 50 weight percent of hollow glass microspheres.

30. A method for reinforcing a hollow structural member formed by at least two off-center passages that are connected in a joint comprising providing a carrier portion having a plurality of extensions extending from a base portion corresponding to the hollow structure with each of the extensions being connected together by the first portion to form a continuous integral external surface of each pair of extensions and with each extension being longer than the base portion, apply a layer of the thermally expandable adhesive material to the carrier portion, place each of the extensions in a respective passage with the base portion remaining in the joint of the passages, heat the base portion and the adhesive layer, activate the adhesive layer, bond the adhesive layer to the structural member, and cool the structural member and the heated layer.

The method of claim 30, wherein there are three off-center connection passages and three corresponding extensions, and placing each extension in a corresponding passage.

32. The method of claim 31 of each of the extensions and the base portion is tubular in shape, and includes the step of filling the tubular shape with a foam core.

33. The method of claim 31, each of the extensions and the base portion is tubular in shape and includes maintaining a hollow, hollow tubular shape.

34. The method of claim 30, wherein the off-center connecting passages are placed in a joint between the roof and the pillar of an automotive vehicle.