Baffle assembly

Patent metadata

Field	Value
Publication number	US-8967327-B2
Application number	US-201313796250-A
Country	US
Kind code	B2
Filing date	Mar 12, 2013
Priority date	Mar 20, 2012
Publication date	Mar 3, 2015
Grant date	Mar 3, 2015

Abstract

A device and method for a baffling, sealing, or reinforcement that includes one or more flow channel structures selectively formed in a carrier for achieving improved connection between the carrier and an expandable material attached thereto.

First claim

The invention claimed is:

1. A baffle assembly comprising:
i. a carrier including:
a. an inner portion that includes a first outward facing surface and at least one sloping channel defined in and recessed relative to the first surface;
b. a peripheral portion that generally surrounds the inner portion and includes at least one outwardly projecting ledge, the inner portion and the peripheral portion being connected along at least one barrier wall that at least partially circumscribes the inner portion and which intersects with at least one of the sloping channels;
c. at least one finger member that is located within in the inner portion and projects outwardly from within at least one of the sloping channels at an angle between 0 and 180° relative to the outwardly projecting ledge;

ii. a resinous material that includes a polymer that (i) is adapted for thermal expansion upon activation by heat that is located within at least one sloping channels, (ii) is located on at least a portion of the outwardly projecting ledge; and (iii) at least partially covers the at least one finger member and (iv) is retained on the carrier at least partially due to a mechanical connection with the at least one finger member.

2. The baffle assembly of claim 1 , wherein the first surface of the inner portion is generally flat.

3. The baffle assembly of claim 1 , wherein the outwardly projecting ledge only partially circumscribes the at least one barrier wall.

4. The baffle assembly of claim 1 , wherein the at least one finger member is oriented at an angle of approximately 90 relative to the first outward facing surface.

5. The baffle assembly of claim 1 , wherein the at least one finger is configured as an elongated structure that deforms upon flow of the resinous material.

6. The baffle assembly of claim 1 , wherein the at least one finger member projects from a wall defining the sloping channel outwardly in a direction toward the first surface.

7. The baffle assembly of claim 1 , wherein the at least one finger member has a hook shaped free end portion.

8. The baffle assembly of claim 1 , wherein the resinous material includes a plurality of masses that are located on the outwardly projecting ledge and are intermittently spaced relative to each other.

9. The baffle assembly of claim 1 , wherein the resinous material is such that it can be melted for injection molding at a first temperature, and thereafter be activated by heating at an activation temperature above the first temperature for causing it to expand.

10. The baffle assembly of claim 1 , wherein the carrier includes an integrated mechanical attachment device that projects away from the inner portion and is substantially juxtaposed with either or both of the inner portion or at least one of the sloping channels so that the attachment device can be located within a hole of a wall defining a cavity of a transportation vehicle, and the resinous material will be in opposing relation to the hole for filling the hole upon activation of the resinous material by exposure to a temperature above its activation temperature.

11. A baffle assembly for use in a cavity of a transportation vehicle, comprising:
i. a carrier including:
a. an inner portion that includes a first outward facing surface that is generally flat and at least one sloping channel defined in and recessed relative to the first surface;
b. a peripheral portion that generally surrounds the inner portion and includes at least one outwardly projecting ledge, the inner portion and the peripheral portion being connected along at least one barrier wall that at least partially circumscribes the inner portion and which intersects with at least one of the sloping channels;
c. at least one finger member formed as an elongated structure that is located within in the inner portion and projects outwardly from within at least one of the sloping channels at an angle of approximately 90° relative to the first outward facing surface;

ii. a resinous material that includes a polymer that (i) is adapted for thermal expansion upon activation by heat that is located within at least one sloping channels, (ii) is located on at least a portion of the outwardly projecting ledge; and (iii) at least partially covers the at least one finger member and (iv) is retained on the carrier at least partially due to a mechanical connection with the at least one finger member such that the resinous material deforms the finger member upon flowing of the resinous material at activation.

12. The baffle assembly of claim 11 including more than two sloping channels.

13. The baffle assembly of claim 11 including more than one finger member in the at least one sloping channel.

14. The baffle assembly of claim 1 wherein at least a portion of the resinous material is located in direct planar contact with the first outward facing surface in portions of the first outward facing surface other than the at least one sloping channel.

15. The baffle assembly of claim 11 , wherein the at least one finger member has a hook shaped free end portion.

16. The baffle assembly of claim 11 including one or more fasteners extending outwardly from the carrier for attaching the carrier to a cavity wall.

17. The baffle assembly of claim 11 , wherein the resinous material is such that it can be melted for injection molding at a first temperature, and thereafter be activated by heating at an activation temperature above the first temperature for causing it to expand.

18. The baffle assembly of claim 11 , wherein a bottom of each sloping channel sits above the outwardly projecting ledge.

Assignees

• Zephyros Inc

Inventors

• Synnestvedt Blake

Classifications

• B62D29/002 Primary

  a foamable synthetic material or metal being added in situ (shaping of substances in a plastic state by foaming, in general B29C44/00) · CPC title

• B65D90/52 Primary

  Anti-slosh devices (vehicle fuel tanks with means modifying or controlling distribution or motion of fuel, e.g. to prevent noise, surge, splash or fuel starvation B60K15/077) · CPC title

• Y10T428/24017

  Hook or barb · CPC title