Abstract:
The present invention relates to an acoustic baffle device for sealing a cavity of a vehicle body at a predetermined cross section of the cavity, comprising a piece of sealing material that is formed in a shape corresponding to but being smaller than the shape of the cross section of the cavity. The acoustic baffle device of the invention is characterized in having a flap assembly having a lower neck defining a passage for a flexible tube or a similar device, said lower neck having a flap secured in closed position by a locking device and being connected preferably to the lower end of the lower neck through means that permit the reversible opening of the above-defined passage. Furthermore, the present invention relates to a flap assembly useful for such an acoustic baffle device, and to a process for sealing a cavity of a vehicle body at a predetermined cross section of the cavity.
Abstract:
A reinforcement (10) includes a material layer (18) disposed on a carrier (12) that includes integrally formed support features (20), such as ribs (22), holes (26), pins (28), or a combination thereof, and/or a connector pin (36) that deforms to secure the material layer (18) to the carrier (12). The support features (20) reduce the weak interface between the material layer (18) and the carrier (12) by improving bonding of the material layer (18) to the carrier (12).
Abstract:
A structural member includes one or more walls that define a cavity. A system for reinforcing the cavity includes a substantially rigid carrier configured to reside in the cavity. The carrier includes a pathway disposed in the carrier that provides an aperture between an exterior surface of the carrier and an interior surface of the carrier. An adhesive is disposed in a gap between at least a portion of the exterior surface of the carrier and the wall of the structural member. The adhesive is disposed proximate to the pathway.
Abstract:
A reinforcement includes a carrier having a plurality of exterior walls spaced from one another. The carrier defines a channel extending substantially parallel to a longitudinal axis defined by a cavity. A material layer is disposed on at least one of the exterior walls within the channel such that an electrocoating material is able to flow through the channel before the material layer is expanded and the channel is substantially filled after the material layer is expanded.
Abstract:
A structural reinforcement material (20) is provided that includes a base material selected fr om the group consisting of thermosets, low viscosity thermoplastics with short transition phas es and low viscosities, low melting point metallic alloys, and combinations thereof. At STP, the structural reinforcement material (20) is a solid or a formable dough or a mixture thereof. When heated to an activation temperat ure, the structural reinforcement material (20) becomes flowable into a cavity (10). Following cooling, the structural reinforcement material (20) is a solid or a thermoset with a strength sufficient to reinforce the cavity (10). A structural reinforcement insert (111) comprising the structural reinforcement ma terial (20) is also provided, as is a reinforced cavity (10) of an automobile (2) and a method of reinforcing a cavity (10).
Abstract:
A method of forming a baffle or reinforcement (170) comprises molding an expandable material (180) in a first cavity (130) of a mold (105) and molding a carrier material (175) onto the expandable material in a second cavity (135) of the mold (105).
Abstract:
Disclosed are various embodiments of a structural reinforcement system (20). The system reinforces hollow cavities within various products to increase the structural rigidity of the product. The system generally includes a rigid carrier (22), a bonding material (40), and an insert (30). The rigid carrier provides the primary structural reinforcement within the cavity, and also serves as a substrate to carry the bonding material. The insert is provided to increase the structural rigidity of the reinforcement system.
Abstract:
A baffle (10) is provided that includes at least one carrier (12) and a sealer (18) disposed in a recess (16). When placed in a cavity, such as a vehicle cavity, sealer (18) also expands into the cavity to seal the cavity. Baffle (10) can be modified by including an insert (28) within carrier (12) to increase the weight, density, and structural rigidity of baffle (10), without altering the exterior dimensions of baffle (10). A baffle (10) that includes an insert (28) can be customized based on a particular application, without requiring time-consuming and expensive tooling changes.
Abstract:
Exemplary reinforced structures, e.g., panel structures, and methods of making the same are disclosed. A reinforced structure may include a panel support extending along a panel. The panel support may be relatively rigid in comparison to the panel. The structure may further include an expandable support having a body portion mounted on the panel support. The body portion may be formed of an expandable material such that the body portion is configured to engage the panel upon expansion, thereby providing an expanded support acting between the panel and the panel support after expansion.
Abstract:
A exemplary method of, for instance, forming a baffle (100) or reinforcer includes extruding an expandable material (110) to have a particular cross-sectional profile, inserting the expandable material (110) into a molding tool (135), cutting the expandable material (110) to a predetermined length within the molding tool (135), and overmolding a carrier material (105) onto a portion of the expandable material (110) within the molding tool (135).