Acoustic spray foam control system and method

An acoustic spray foam control method for a sunroof drain tube area in a vehicle, comprising:

• providing an acoustic spray foam control baffle configured for mounting within the sunroof drain tube area;
• installing the acoustic spray foam control baffle within the sunroof drain tube area;
• installing a sunroof drain tube into the sunroof drain tube area by passing the sunroof drain tube through the acoustic spray foam control baffle;
• and
• injecting an acoustic spray foam into the sunroof drain tube area with the acoustic spray foam control baffle controlling the flow of the acoustic spray foam within the sunroof drain control area,
• wherein the sunroof drain control area is defined by an outer pillar member, an inner pillar member and at least one reinforcement member disposed between the outer and inner pillar members, the inner pillar member defining an injection inlet aperture into which the acoustic spray foam is injected, and
• wherein the injection inlet aperture and the acoustic spray foam control baffle are arranged such that injection of the acoustic spray foam through only the injection inlet aperture fills an inner cavity defined between the inner pillar member and the at least one reinforcement member and an outer cavity defined between the outer pillar member and the at least one reinforcement member.

An acoustic spray foam control system for a sunroof drain tube area in a vehicle, comprising:

• an acoustic spray foam control baffle mounted within the sunroof drain tube area of the vehicle;
• a sunroof drain tube installed in the sunroof drain tube area by passing through the acoustic spray foam control baffle;
• an acoustic spray foam injected into the sunroof drain tube area with flow of the acoustic spray foam controlled by the acoustic spray foam control baffle;
• and
• a curved projecting flange projecting radially outward from a first section of the acoustic spray foam control baffle disposed between a pair of the spaced apart flange portions for inhibiting dispersal of the acoustic spray foam into an aperture area disposed adjacent an fastener aperture defined in the pillar.

An acoustic spray foam control system for a sunroof drain tube area in a vehicle, comprising:

• an acoustic spray foam control baffle mounted within the sunroof drain tube area of the vehicle;
• a sunroof drain tube installed in the sunroof drain tube area by passing through the acoustic spray foam control baffle;
• an acoustic spray foam injected into the sunroof drain tube area with flow of the acoustic spray foam controlled by the acoustic spray foam control baffle;
• an inner pillar member;
• an outer pillar member fixed to the inner pillar member to define a cavity therebetween in which the acoustic spray foam control baffle is complementarily received;
• and
• at least one reinforcement member disposed between the inner and outer pillar members and fixedly secured to the inner and outer pillar members, wherein the inner pillar member defines an injection inlet aperture into which the acoustic spray foam is injected, and wherein the acoustic spray foam control baffle is accommodated within an inner cavity defined between the inner pillar member and the at least one reinforcement member, and
• wherein the acoustic spray foam control baffle is configured such that injection of the acoustic spray foam into the injection inlet aperture results in the acoustic spray foam being received in the inner cavity and an outer cavity defined between the outer pillar member and the at least one reinforcement member.

An acoustic spray foam control baffle for positioning within a pillar on a vehicle, comprising:

• first and second end radial flanges for inhibiting dispersal of acoustic spray foam within a cavity defined in the pillar;
• a middle radial flange disposed between and spaced apart from the first and second end radial flanges;
• a first longitudinal section disposed between the first end radial flange and the middle radial flange;
• and
• a second longitudinal section disposed between the second end radial flange and the middle radial flange,
• wherein the first, second and middle radial flanges define apertures for accommodating a sunroof drain tube.