US Patent No: 6,422,575

Number of patents in Portfolio can not be more than 2000

Expandable pre-formed plug

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Importance

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Abstract

The present invention is directed to an expandable pre-formed plug that is suitable for sealing and/or structurally reinforcing a structure having surfaces defining a space therebetween. The plug is comprised of at least an expandable inner core having an outer surface and a transportable outer skin that preferably substantially encapsulates the core. In a preferred embodiment, the shape of the unexpanded plug is designed to mate with the surfaces that define a space therebetween upon expansion. The adhesive skin is generally dry to the touch at room temperature, however, upon initiation of expansion, the inner core expands and the surrounding skin is displaced in a coordinated manner. After some period of expansion, the outer skin preferably durably adheres or bonds to the walls of the surfaces defining a space therebetween and the outer surface of the core. A method for using such a plug is also disclosed.

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First Claim

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Patent Owner(s)

Patent OwnerAddressTotal Patents
ZEPHYROS, INC.ROMEO, MI132
L&L PRODUCTS, A CORPORATION OF MICHIGANROMEO, MI2

International Classification(s)

Inventor(s)

Inventor Name Address # of filed Patents Total Citations
Apfel, David D Attica, MI 2 101
Czaplicki, Michael J Rochester, MI 61 1793

Cited Art

Patent Info (Count) # Cites Year
 
HENKEL CORPORATION (19)
5,884,960 Reinforced door beam 134 1996
6,058,673 Internal reinforcement for hollow structural elements 71 1997
6,068,424 Three dimensional composite joint reinforcement for an automotive vehicle 88 1998
6,099,948 Encapsulation of pre-expanded elastomeric foam with a thermoplastic 81 1998
6,168,226 Composite laminate automotive structures 107 1998
5,992,923 Reinforced beam assembly 96 1998
6,096,403 Reinforced structural members 104 1998
6,233,826 Method for reinforcing structural members 88 1998
6,237,304 Laminate structural bulkhead 96 1998
6,276,105 Laminate reinforced beam with tapered polymer layer 81 1999
6,003,274 Lightweight laminate reinforcing web 117 1999
6,092,864 Oven cured structural foam with designed-in sag positioning 98 1999
6,149,227 Reinforced structural assembly 75 1999
6,270,600 Reinforced channel-shaped structural member methods 94 1999
6,079,180 Laminate bulkhead with flared edges 78 1999
6,103,784 Corrosion resistant structural foam 61 1999
6,189,953 Reinforced structural assembly 78 2000
6,272,809 Three dimensional laminate beam structure 75 2000
6,287,666 Reinforced structural members 89 2000
 
SIKA CORPORATION (9)
5,373,027 Dry expansible sealant and baffle composition and product 80 1993
5,506,025 Expandable baffle apparatus 114 1995
5,731,069 Composite gage and drain hole sealer 27 1995
5,725,272 Drain assembly for acoustic baffle system 80 1996
6,150,428 Expansion temperature tolerant dry expandable sealant and baffle product and method of preparing same 84 1999
6,199,940 Tubular structural reinforcing member with thermally expansible foaming material 98 2000
6,253,524 Reinforcing member with thermally expansible structural reinforcing material and directional shelf 76 2000
6,305,136 Reinforcing member with beam shaped carrier and thermally expansible reinforcing material 77 2000
6,281,260 Expansion temperature tolerant dry expandable sealant and baffle product 83 2000
 
NOVAMAX TECHNOLOGIES HOLDINGS, INC. (8)
4,751,249 Reinforcement insert for a structural member and method of making and using the same 144 1985
4,901,500 Lightweight composite beam 116 1988
4,908,930 Method of making a torsion bar 87 1988
4,922,596 Method of manufacturing a lightweight composite automotive door beam 117 1988
4,995,545 Method of reinforcing a structure member 110 1988
4,978,562 Composite tubular door beam reinforced with a syntactic foam core localized at the mid-span of the tube 183 1990
5,755,486 Composite structural reinforcement member 154 1995
5,888,600 Reinforced channel-shaped structural member 117 1996
 
ZEPHYROS, INC. (8)
5,358,397 Apparatus for extruding flowable materials 106 1993
5,985,435 Magnetized hot melt adhesive articles 106 1996
5,648,401 Foamed articles and methods for making same 46 1996
6,103,341 Self-sealing partition 89 1997
6,033,300 Automotive vehicle HVAC rainhat 72 1998
6,131,897 Structural reinforcements 98 1999
6,296,298 Structural reinforcement member for wheel well 85 2000
6,311,452 Structural reinforcements 90 2000
 
GENERAL MOTORS CORPORATION (6)
4,610,836 Method of reinforcing a structural member 111 1984
4,695,343 Method of reinforcing a structural member 62 1986
4,732,806 Structural member comprising glass macrospheres 64 1987
4,901,395 Self-sealing heat activated grommet 56 1989
5,806,919 Low density-high density insert reinforced structural joints 82 1996
5,988,734 Passenger vehicle structure 43 1998
 
NEO-EX LAB, INC. (4)
5,806,915 Support structure for supporting foamable material on hollow structural member 80 1996
5,642,914 Support structure for supporting foamable material on hollow structural member 87 1996
5,649,400 Support structure for supporting foamable material on hollow structural member 35 1996
6,247,287 Structure and method for closing and reinforcing hollow structural members 90 1998
 
NISSAN MOTOR CO., LTD. (4)
5,102,188 Vehicle body structure producing method and flowable resin damming arrangement therefor 67 1989
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5,707,098 Door structure for vehicle 44 1995
6,059,342 Car body structure 57 1999
 
WILHELM KARMANN GMBH (4)
5,803,533 Motor vehicle body, particularly for a convertible 37 1996
6,090,232 Component made from a metallic foam material 33 1997
6,135,542 Car body part, particularly a contoured frame member 69 1997
6,094,798 Component made from a metallic foam material 30 1999
 
CHRYSLER GROUP LLC (3)
5,934,737 Dynamic impact energy absorbing assembly 29 1996
6,129,410 Apparatus for reinforcing a body side panel of a motor vehicle 50 1998
6,196,621 Apparatus for transferring impact energy from a tire and wheel assembly of a motor vehicle to a sill 66 2000
 
FORD GLOBAL TECHNOLOGIES, INC. (3)
4,917,435 Truck cab construction 46 1989
5,395,135 Energy absorbing vehicle door and side panels 63 1994
5,560,672 Energy absorbing beam 55 1996
 
HENKEL AG & CO. KGAA (3)
6,004,425 Rubber-based structural white-shell adhesives 50 1997
5,994,422 Hot-curing rubber foams with high structural strength 42 1997
6,096,791 Sulphur-free expanding, hot hardening shaped parts 40 1999
 
DENOVUS LLC (2)
6,174,932 Curable sealant composition 53 1998
6,277,898 Curable sealant composition 47 1998
 
ESSEX SPECIALTY PRODUCTS, INC. (2)
4,803,108 Honeycomb reinforcing sheet for the reinforcement of panels and method of reinforcing panels 58 1987
6,153,709 Chip resistant, vibration damping coatings for vehicles 42 1999
 
FORD MOTOR COMPANY (2)
4,397,490 Low profile bumper 54 1981
4,559,274 Composite components of sandwich construction 45 1983
 
HENKEL KOMMANDITGESELLSCHAFT AUF AKTIEN (2)
5,932,680 Moisture-curing polyurethane hot-melt adhesive 91 1996
6,165,588 Reinforcement of hollow sections using extrusions and a polymer binding layer 109 1998
 
HONDA GIKEN KOGYO KABUSHIKI KAISHA (2)
4,762,352 Synthetic resin bumper assembly 72 1986
5,941,597 Structural member of vehicle 68 1997
 
METALDYNE TUBULAR PRODUCTS, INC. (2)
5,580,120 Vehicle door intrusion beam 50 1995
5,785,376 Vehicle door beam 53 1996
 
SIKA AG, VORM. KASPAR WINKLER & CO. (2)
5,894,071 Two-component adhesive-, sealing- or coating composition and it's use 50 1996
6,006,484 Sound-damping partition 69 1998
 
AB VOLVO (1)
6,073,991 Stress-bearing assembly 48 1997
 
AIRBUS OPERATIONS SAS (1)
8,028,960 Flight deck layout for aircraft 16 2007
 
BASF AKTIENGESELLSCHAFT (1)
5,122,398 Recyclable bumper system 56 1990
 
BRITISH GAS PLC (1)
5,878,784 Pipe blocking technique 38 1997
 
CHRYSLER CORPORATION (1)
5,344,208 Reinforcement assembly for vehicle panels 78 1991
 
DAIMLERCHRYSLER AG (1)
6,152,260 Method of filling cavities in workpieces or semi-finished products and structural components parts for mounting on or in a motor vehicle 27 1998
 
DAVIDSON TEXTRON INC. (1)
5,577,784 Vehicle bumper 41 1994
 
DEXTER CORPORATION (1)
4,989,913 Barrier for use in hollow channel in motor vehicle body and method for producing same 33 1990
 
E. I. DU PONT DE NEMOURS AND COMPANY (1)
5,266,133 Dry expansible sealant and baffle composition and product 106 1993
 
ESSEX COMPOSITE SYSTEMS, 29605 PARKWAY, ROSEVILLE, MICHIGAN 48066, A CORP. OF MICHIGAN (1)
4,853,270 Knee blocker for automotive application 118 1988
 
ESSEX COMPOSITE SYSTEMS, A GENERAL PRTNERSHIP OF MICHIGAN (1)
4,923,902 Process and compositions for reinforcing structural members 146 1988
 
ESSEX STRUCTURAL PARTS, INC., 615 GRISWOLD, DETROIT, MICHIGAN 48226 A MICHIGAN CORP. (1)
4,861,097 Lightweight composite automotive door beam and method of manufacturing same 131 1987
 
GREENWICH PHARMACEUTICALS INCORPORATED (1)
4,813,690 Sealing member 83 1987
 
HENKEL KOMMANDITGESELLSCHAFT AUF AKTIEN HENKEL KGA (1)
4,836,516 Filled tubular torsion bar and its method of manufacture 113 1988
 
HP PELZER (AUTOMOTIVE SYSTEMS), INC. (1)
6,197,403 Integral sound absorber and water deflector door panel 60 1998
 
HYTEC, INC. (1)
6,102,379 Torsion springs with visco-elastic damping 29 1997
 
IGM GROUP B.V. (1)
6,232,433 Radiation curable polyesters 51 1997
 
IIDA INDUSTRY CO., LTD. (1)
4,898,630 Thermosetting highly foaming sealer and method of using it 72 1988
 
IIDA SANGYO KABUSHIKI KAISHA (1)
5,804,608 Heat-foamable filling reinforcement and reinforced closed-section structural-member making use of the same 40 1996
 
IRBIT RESEARCH & CONSULTING AG (1)
5,072,952 Sealing element 45 1990
 
KYOHO MACHINE WORKS, LTD. (1)
6,082,811 Reinforcement for vehicle hollow structural member, having decreasing-thickness end portions 34 1998
 
L&L PRODUCTS, A CORPORATION OF MICHIGAN (1)
6,263,635 Tube reinforcement having displaceable modular components 85 1999
 
L&L PRODUCTS, INC. (1)
4,463,870 Closure plate for an opening 80 1983
 
LEAR CORPORATION (1)
5,786,394 Durable, energy-absorptive EPP/PUR structural composites 38 1996
 
MAGNA EXTERIOR SYSTEMS GMBH OF OBERTSHAUSEN (1)
5,766,719 Composite material 101 1995
 
MAGNA PEBRA GMBH (1)
6,102,473 Molding for covering longitudinal member of an automobile 36 1998
 
MANGA PEBRA GMBH (1)
5,984,389 Bumper 46 1997
 
MANNESMANN AKTIENGESELLSCHAFT (1)
5,255,487 Door reinforcement tube 56 1991
 
MASCOTECH AUTOMOTIVE SYSTEMS GROUP, INC. (1)
4,457,555 Conversion of vehicle bodies 57 1981
 
MELEA LIMITED (1)
4,613,177 Vehicle bumper 34 1985
 
MINNESOTA MINING AND MANUFACTURING COMPANY (1)
5,902,656 Dampers for internal applications and articles damped therewith 50 1996
 
MOLLER PLAST GMBH (1)
6,315,938 Method for foaming or foam-coating components 70 2000
 
MPA DIVERSIFIED PRODUCTS CO. (1)
5,124,186 Composite tubular door beam reinforced with a reacted core localized at the mid-span of the tube 181 1990
 
MPA DIVERSIFIED PRODUCTS, INC. (1)
4,769,391 Reinforcement insert for a structural member and method of making and using the same 96 1987
 
NEO-EX LABO (1)
5,904,024 Mount construction of foam substrate in hollow structures 60 1997
 
NITTO ELECTRIC INDUSTRIAL CO., LTD. (1)
4,378,395 Reinforcing material 73 1982
 
NOBLE POLYMERS, LLC (1)
6,146,565 Method of forming a heat expandable acoustic baffle 65 1998
 
ORBSEAL LLC (1)
5,040,803 Cavity sealing arrangement and method 39 1990
 
PEGUFORM FRANCE (1)
6,050,630 Molded composite stack 42 1997
 
PULLMAN COMPANY, THE (1)
5,885,688 Steel reinforced filled polymer torque rod 27 1996
 
SANDIA NATIONAL LABORATORIES (1)
6,110,982 Epoxy foams using multiple resins and curing agents 31 1999
 
SIKA CHEMIE GMBH (1)
6,077,884 Aqueous dispersion of epoxy resin and blend of epoxy resin-polyoxyalkylene amines 50 1998
 
SUBJECT TO AGREEMENT RECITED SEE DOCUMENT FOR DETAILS. (1)
4,238,540 Fiber reinforced composite shaft with metallic connector sleeves mounted by connector ring interlock 89 1979
 
T.A.L.C. LTD. (1)
5,888,642 Syntactic foam core material for composite structures 45 1996
 
THOR TECH, INC. (1)
6,022,066 Door extension for vehicle doors 28 1998
 
TII INDUSTRIES, INC. (1)
5,575,526 Composite laminate beam for radiator support 158 1994
 
TOKAI RUBBER INDUSTRIES, LTD. (1)
5,866,052 Process of manufacturing structural body for automotive vehicle 42 1997
 
ULTRAFRAME PLC OF ENTERPRISE WORKS (1)
5,901,528 Building elements 33 1997
 
VINIDEX PTY LIMITED (1)
6,053,210 Expandable plug and control method 38 1996
 
XCORP, INC. (1)
5,819,408 Recyclable, low cost, collision-resistant automobile chassis and body 61 1996
 
YMOS AKTIENGESELLSCHAFT INDUSTRIEPRODUKTE (1)
5,855,094 Motor vehicle door 27 1996
 
OTHER [CHECK PATENT PROFILE FOR ASSIGNMENT INFORMATION] (6)
4,440,434 Vehicle body construction 71 1981
4,705,716 Integral car body made of composite material 52 1986
4,984,406 Building panel 73 1989
5,652,039 Sandwich panel for angular forming 37 1995
5,871,849 Wood substitute turning blank and method of making the same 26 1997
5,901,752 Inflatable apparatus for sealing a pipeline 41 1998

Patent Citation Ranking

Forward Cites

Patent Info (Count) # Cites Year
 
ZEPHYROS, INC. (66)
6,820,923 Sound absorption system for automotive vehicles 45 2000
6,634,698 Vibrational reduction system for automotive vehicles 54 2001
6,855,652 Structurally reinforced panels 28 2001
6,729,425 Adjustable reinforced structural assembly and method of use therefor 42 2001
6,941,719 Structural reinforcement 35 2001
6,777,049 Structural foam 40 2001
7,011,315 Expandable pre-formed plug 16 2002
7,169,344 Method of reinforcing at least a portion of a structure 1 2002
6,607,238 Structural reinforcement member for wheel well 52 2002
6,641,208 Heat activated reinforcing sleeve 51 2002
6,811,864 Tacky base material with powder thereon 46 2002
6,786,533 Structural reinforcement system having modular segmented characteristics 53 2002
6,575,526 Hydroform structural reinforcement system 58 2002
6,793,274 Automotive rail/frame energy management system 47 2002
7,318,873 Structurally reinforced members 10 2003
6,969,551 Method and assembly for fastening and reinforcing a structural member 18 2003
7,077,460 Reinforcement system utilizing a hollow carrier 29 2003
7,144,071 Multi segment parts 20 2003
6,921,130 Structural reinforcement system for automotive vehicles 31 2003
7,004,536 Attachment system and method of forming same 13 2003
6,920,693 Dynamic self-adjusting assembly for sealing, baffling or structural reinforcement 41 2003
6,923,499 Multiple material assembly for noise reduction 23 2003
6,928,736 Method of reinforcing an automobile structure 37 2003
6,883,858 Structural reinforcement member and method of use therefor 6 2003
7,041,193 Method of adhering members and an assembly formed thereby 8 2003
7,105,112 Lightweight member for reinforcing, sealing or baffling 14 2003
7,194,804 Method of forming a hydroform 6 2003
7,313,865 Process of forming a baffling, sealing or reinforcement member with thermoset carrier member 12 2003
6,953,219 Reinforcing members 33 2003
6,880,657 Adjustable reinforced structural assembly and method of use therefor 28 2004
7,267,738 Synthetic material and methods of forming and applying same 3 2004
6,955,593 HVAC protection system for automotive vehicles 19 2004
7,111,899 Structural reinforcement member and method of use therefor 8 2004
6,890,021 Structural reinforcement system having modular segmented characteristics 36 2004
7,255,388 Reinforcing members 14 2004
7,114,763 Automotive rail/frame energy management system 14 2004
7,479,245 Process for applying a material to a member 0 2004
6,938,947 Structural reinforcement system for automotive vehicles 27 2004
6,905,745 Structural foam 28 2004
7,249,415 Method of forming members for sealing or baffling 7 2004
7,025,409 Automotive rail/frame energy management system 21 2004
7,469,459 System and method employing a porous container for sealing, baffling or reinforcing 7 2004
6,932,421 Structural reinforcement member and method of use therefor 28 2004
7,160,491 Structural reinforcement system for automotive vehicles 13 2005
7,290,828 Baffle system 11 2005
7,479,246 Overmoulding 6 2005
7,790,280 Structural reinforcement 0 2005
7,784,186 Method of forming a fastenable member for sealing, baffling or reinforcing 2 2005
7,478,478 Method of providing reinforcing members 3 2005
7,275,985 HVAC protection system for automotive vehicles 0 2005
7,374,219 Structural reinforcement member and method of use therefor 7 2005
7,494,179 Member for baffling, reinforcement or sealing 12 2006
7,503,620 Structural reinforcement member and method of use therefor 15 2006
7,296,847 Reinforcement system utilizing a hollow carrier 7 2006
7,926,179 Reinforcements, baffles and seals with malleable carriers 0 2006
7,484,946 Method and assembly for locating material within a structure 4 2006
8,163,116 Joints and a system and method of forming the joints 2 2007
7,941,925 Method of forming members for providing sealing or baffling 1 2007
8,128,780 Reinforcement system utilizing a hollow carrier 0 2007
8,002,332 Structural mounting insert 1 2008
7,695,040 Structural reinforcement member and method of use therefor 0 2008
8,181,327 Mechanical method for improving bond joint strength 1 2009
8,029,222 Push-pin fastening system 0 2009
7,984,919 Structural mounting insert having a non-conductive isolator 1 2009
8,079,146 Reinforcements, baffles and seals with malleable carriers 1 2010
8,430,449 Structural mounting insert 0 2011
 
DOW GLOBAL TECHNOLOGIES INC. (6)
7,041,355 Structural reinforcement parts for automotive assembly 2 2001
6,896,320 Reinforced structural body 13 2003
7,097,794 Vehicular structural members and method of making the members 4 2003
7,084,210 Heat activated epoxy adhesive and use in a structural foam insert 0 2003
7,250,124 Structural reinforcement article and process for preparation thereof 1 2004
7,838,100 Vehicular structural members and method of making the members 2 2006
 
HALLIBURTON ENERGY SERVICES, INC. (4)
7,938,186 Casing shoes and methods of reverse-circulation cementing of casing 1 2007
7,621,336 Casing shoes and methods of reverse-circulation cementing of casing 8 2007
7,621,337 Casing shoes and methods of reverse-circulation cementing of casing 3 2007
7,503,399 Casing shoes and methods of reverse-circulation cementing of casing 6 2007
 
INTERFACE SOLUTIONS, INC. (4)
6,733,015 Gaskets with controlled flange surface adhesion properties 7 2001
6,923,998 Edge coated gaskets and method of making same 3 2003
7,278,639 Edge coated gaskets and method of making same 4 2003
7,014,193 Gasket with selectively positioned seal enhancement zones 1 2004
 
BOSTON SCIENTIFIC SCIMED, INC. (1)
7,723,422 Functionalized block copolymers 1 2005
 
IIDA INDUSTRY CO., LTD. (1)
6,887,060 Void filling device 0 2002
 
RPM IRELAND IP LIMITED (1)
6,672,597 Sealing strip for sealing a joint 4 2002
 
SHELL OIL COMPANY (1)
6,896,063 Methods of using downhole polymer plug 8 2003
 
SIKA TECHNOLOGY AG (1)
7,621,373 Acoustic drain 3 2004

Maintenance Fees

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11.5 Year Payment $7400.00 $3700.00 $1850.00 Jan 23, 2014
Fee Large entity fee small entity fee micro entity fee
Surcharge - 11.5 year - Late payment within 6 months $160.00 $80.00 $40.00
Surcharge after expiration - Late payment is unavoidable $700.00 $350.00 $175.00
Surcharge after expiration - Late payment is unintentional $1,640.00 $820.00 $410.00