Load actuated baffle

#The present invention relates generally to a baffling, sealing, or reinforcement member that includes hinge structure for allowing the member to be moveable within a cavity and free of any spring effect during movement.

#The transportation industry continues to require methods of baffling, reinforcement and sealing that provide improved functionality while simultaneously providing reduced weight and cost. Often, the assemblies utilized will be required to move during the installation and manufacturing process. As a result, efforts have been made to produce parts that are movable, any such parts are formed to move but fail to return to the desired location within a cavity. There is thus a need in the art of sealing for parts that are both movable and yet formed to re-locate to a specific location after movement.

#The present teachings meet the aforementioned inert by providing in a first aspect, a method for baffling, reinforcing or sealing of a cavity of a vehicle comprising providing a pre-formed insert. The insert may include a first pre-installation configuration including a carrier structure and an expandable material supported on the carrier structure. The insert may also include a plurality of living hinges, each hinge configured for enabling local elastic deformation of the insert in a respective pre-determined direction. The insert may also include an attachment portion and at least one contact surface located external of the expandable material for defining a generally low-friction surface as compared with the expandable material and formed for spacing the expandable material from an opposing surface during subsequent installation steps. The insert may then be attached to a first substrate. A second substrate may then be attached to the first substrate in overlying relationship with the first substrate for defining a cavity with the insert there between while elastically deforming each of the living hinges of the insert in their respective pre-determined directions so that the insert assumes a second installed configuration different from the first pre-installation configuration. The expandable material may then be activated while the insert is in the second installed configuration for causing it to foam and fill the cavity.

#FIG. 1 shows a perspective view of an illustrative example of carrier of the present teachings.

#FIG. 2 shows a magnified view of hinge of an illustrative example of a baffle structure of the present teachings.

#FIG. 3 shows a perspective view of the hinge of FIG. 2 show as the hinge is moved to a closed position.

#The explanations an 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 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 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.

#This application is related to and claims the benefit of the priority date of U.S. Provisional Application Ser. Nos. 61/616,143, filed on Mar. 27, 2012, and 61/610,289, filed on Mar. 13, 2012. The entirety of these applications is hereby incorporated by reference for all purposes.

#The baffle structure of the present teachings may include a carrier having one or more living hinges. The living hinges facilitate movement of at least a portion of the baffle as the shape of a cavity which the baffle is located changes during a manufacturing process. Thus, as the shape of the cavity changes, the shape of the baffle also changes to conform more precisely with the shape of the cavity. One or more hinges may include a contact surface. The contact surface may contact a wall of the cavity. The contact surface may contact a cavity wall that moves during a manufacturing process so that the movement of the cavity wall causes movement of the carrier due to the contact between the contact surface and cavity wall. The hinge including the contact surface may be the only hinge. Alternatively, the movement of the hinge including the contact surface may cause movement of one or more additional hinges.