Method for improved reinforcement baffling and sealing

A method for reinforcing, baffling, or sealing a vehicle structure comprising:

• providing one or more materials for reinforcing, baffling or sealing a vehicle structure wherein the one or more materials has a horizontal axis, at least one terminating edge, and an initial length;
• forming openings in the one or more materials wherein:
• i. the openings are formed perpendicular to the horizontal axis;
• ii. the openings alternate so that every other opening severs the one or more materials at the at least one terminating edge and the remaining adjacent openings sever the one or more materials at the horizontal axis;
• iii. the forming of the openings removes no material so that waste is minimized;
• stretching the one or more materials to a placement length that is at least 1.3 times the initial length, wherein the placement length corresponds to a length of a location requiring reinforcement, baffling, sealing or any combination thereof;
• applying the one or more stretched materials to the location requiring reinforcement, baffling, sealing or any combination thereof so that the total amount of material applied is less than would be required if the material contained no openings.

A method for reinforcing, baffling, or sealing a vehicle structure comprising:

• providing an expandable material for reinforcing, baffling or sealing a vehicle structure wherein the expandable material has a horizontal axis, two terminating edges, and an initial length;
• die-cutting openings in the expandable material wherein:
• i. the openings are cut perpendicular to the horizontal axis;
• ii. the openings alternate so that every other opening severs the expandable material at the two terminating edges and the remaining adjacent openings sever the expandable material at the horizontal axis so that the openings allow the expandable material to expand to a more consistent height and width than if the material contained no openings;
• iii. the die-cutting of the openings removes no material so that waste is minimized;
• stretching the expandable material to a placement length that is at least 1.5 times the initial length, wherein the placement length corresponds to a length of a location requiring reinforcement, baffling, sealing or any combination thereof;
• applying the stretched expandable material to the location requiring reinforcement, baffling, sealing or any combination thereof so that the total amount of expandable material applied is less than would be required if the expandable material contained no openings.