阅读说明：本技术 防颤动挡板 (Anti-vibration baffle ) 是由 凯尔·靛真 尼古拉斯·阿戈斯蒂尼 埃里克·怀特 丹尼斯·斯科涅辛 于 2018-06-04 设计创作，主要内容包括：披露了一种在运输车辆中使用的挡板组件,该挡板组件包括：载体,该载体包括内部部分,该内部部分包括向上延伸的多个壁；边缘部分,该边缘部分延伸以基本上包围该内部部分；和紧固件,该紧固件在与该多个壁相同的方向上从该边缘部分向上延伸。该挡板还包括树脂密封剂,该树脂密封剂包含聚合物,该聚合物适于在被位于该内部部分的至少一部分上的热量激活时热膨胀,其中该边缘部分基本上没有任何密封剂。(Disclosed is a baffle assembly for use in a transportation vehicle, the baffle assembly comprising: a carrier comprising an interior portion comprising a plurality of walls extending upwardly; an edge portion extending to substantially enclose the inner portion; and a fastener extending upwardly from the edge portion in the same direction as the plurality of walls. The baffle further includes a resin sealant comprising a polymer adapted to thermally expand when activated by heat located on at least a portion of the inner portion, wherein the edge portion is substantially free of any sealant.)

1. A baffle assembly for use in a cavity of a transit vehicle, the baffle assembly comprising:

i. a vector, the vector comprising:

a. an inner portion comprising a plurality of walls extending upwardly;

b. an edge portion extending to substantially enclose the inner portion;

c. a fastener extending upwardly from the edge portion in the same direction as the plurality of walls;

a resin sealant comprising a polymer adapted to thermally expand when activated by heat located on at least a portion of the inner portion;

wherein the edge portion is substantially free of any sealant prior to activation of the sealant.

2. The baffle of claim 1, wherein the plurality of walls extend upwardly to meet a top surface of the inner portion, wherein the top surface is substantially parallel to the edge portion.

3. The baffle of claim 1 or 2, wherein the edge portion completely circumscribes the inner portion.

4. The baffle of any one of claims 1 to 3, wherein the sealant extends along a portion of one or more of the plurality of walls.

5. The baffle of claim 2, wherein the sealant extends over a portion of a top surface of the inner portion.

6. The baffle of any one of claims 1 to 5, wherein the inner portion comprises a top surface located at least about 1mm, at least about 3mm, or even at least about 5mm above the edge portion.

7. The baffle of any one of claims 1 to 6, wherein the resin material is such that it can be melted at a first temperature for injection molding and then activated by heating at an activation temperature higher than the first temperature to expand it.

8. The baffle of any one of claims 1 to 7, wherein the fastener extends substantially perpendicular to the edge portion.

9. The fender of any one of claims 1 to 8 wherein the fastener is adapted to extend into an opening located on a transit vehicle component.

10. The baffle of any one of claims 1 to 9, wherein one or more walls of the plurality of walls are arranged at an angle substantially perpendicular to the edge portion.

11. The baffle of any one of claims 1 to 10, wherein the top surface of the inner portion is a continuous surface substantially free of any openings.

12. The baffle of any one of claims 1 to 11, wherein one or more walls of the plurality of side walls comprise one or more openings.

13. The baffle plate of any one of claims 1 to 12, comprising at least four sidewalls.

14. The baffle of any one of claims 1 to 13, wherein the resin sealant extends as a single continuous piece over the inner portion.

15. The baffle of any one of claims 1 to 14, wherein at least a portion of the inner portion remains free of any resin sealant material prior to activation of the resin sealant material.

16. The baffle plate as claimed in any one of claims 1 to 15, wherein the baffle plate is adapted to extend into a vehicle cavity.

17. The baffle of any one of claims 1 to 16, comprising at least two fasteners.

18. The baffle of any one of claims 1 to 17, wherein the resin sealant circumscribes the inner portion.

19. A method for forming the baffle plate of any one of claims 1 to 18, the method comprising:

injecting a polymeric carrier material into a first cavity of a mold to form the carrier;

the resinous sealant material is injected into the second cavity of the mold such that the sealant is located on an interior portion of the baffle plate, but not on an edge portion of the baffle plate.

20. Use of a baffle according to any of claims 1 to 18 for preventing flutter and/or read-through in a transport vehicle.

Technical Field

The present teachings generally relate to a baffle and seal member for reducing panel vibration and minimizing read-through.

Background

The transportation industry continues to demand methods of employing baffles, reinforcements, and seals that provide improved functionality while reducing weight and cost. As a result of this lightening effort, the use of thinner materials in combination with the need to adequately join different materials may lead to undesirable vibration and readthrough problems.

Accordingly, it is desirable to provide a structure for improving the attachment between an exterior vehicle panel and an interior vehicle component that minimizes vibration (e.g., chatter) while also minimizing read-through tendencies on exterior panels having relatively thin cross-sections. Therefore, there is a need for an improved method of fixing an interior material and an exterior material to each other in an effort to mitigate some of the negative effects of weight reduction.

Disclosure of Invention

In a first aspect, the present teachings contemplate a baffle assembly for use in a transit vehicle, the baffle assembly comprising: a carrier comprising an interior portion comprising a plurality of walls extending upwardly; an edge portion extending to substantially enclose the inner portion; and a fastener extending upwardly from the edge portion in the same direction as the plurality of walls. The baffle may further comprise a resin sealant comprising a polymer adapted to thermally expand when activated by heat located on at least a portion of the inner portion, wherein the edge portion is substantially free of any sealant.

The plurality of walls may extend upward to meet a top surface of the inner portion, wherein the top surface is substantially parallel to the edge portion. The edge portion may completely circumscribe the inner portion. The sealant may extend along a portion of one or more of the plurality of walls. The sealant may extend over a portion of a top surface of the inner portion. The inner portion may include a top surface located at least about 1mm, at least about 3mm, or even at least about 5mm above the edge portion. The resin material may be such that it can be melted at a first temperature for injection molding and then activated by heating at an activation temperature higher than the first temperature to expand it. The fastener may extend substantially perpendicular to the edge portion.

The fastener may be adapted to extend into an opening located on a component of the transportation vehicle. One or more of the plurality of walls may be disposed at an angle substantially perpendicular to the edge portion. The top surface of the inner portion may be a continuous surface substantially free of any openings. One or more of the plurality of side walls may include one or more openings. The baffle may include at least four sidewalls. The resin sealant may extend as a single continuous piece over the inner portion. At least a portion of the inner portion may remain free of any resin sealant material prior to activation of the resin sealant material. The baffle may be adapted to extend into the vehicle cavity. The baffle may include at least two fasteners. The resin sealant may circumscribe the inner portion.

The teachings herein further provide a method for forming a baffle as described herein, the method comprising: injecting a polymeric carrier material into a first cavity of a mold to form the carrier; and injecting the resin sealant material into the second cavity of the mold such that the sealant is located on an inner portion of the dam, but not on an edge portion of the dam.

The teachings herein also relate to the use of the baffle described herein to prevent chatter and/or read-through in a transportation vehicle.

The teachings herein contemplate an apparatus and method for sealing a cavity with a combination including a carrier material having a raised interior portion, an edge portion, and a fastener, and a resin material.

Drawings

Fig. 1 shows a perspective view of an illustrative example of a baffle assembly of the present teachings.

FIG. 2 illustrates a top plan view of the baffle assembly shown in FIG. 1.

Fig. 3 illustrates a bottom view of the baffle assembly shown in fig. 1.

Fig. 4 shows a perspective view of the baffle assembly of fig. 1 in use.

Detailed Description

The present teachings address one or more of the above needs by providing improved apparatus and methods described herein. The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the teachings, their principles, and their practical application. Those skilled in the art can adapt and apply the teachings in their various forms so as to best suit the needs of their actual use. Therefore, the particular embodiments of the present teachings set forth are not intended to be exhaustive or to limit the present teachings. The scope of the present 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. All articles and references of the present disclosure, including patent applications and publications, are incorporated herein by reference for all purposes. Other combinations are also possible, as will be gleaned from the following claims, which are also incorporated into this written description by reference.

This application relates to and claims the benefit of filing date of U.S. provisional application serial No. 62/514,358 filed on 2.6.2017, the contents of which are hereby incorporated by reference herein for all purposes.

The baffle assembly includes a carrier that can have a variable and non-planar surface topography. The carrier may be formed of a first material and is typically in contact with a second material, which may be different from the first material forming the carrier. The carrier may have an inner portion that may have a first outward surface and a second outward surface that is generally opposite the first outward surface. The inner portion may be at least partially surrounded by the edge portion. The second material (e.g., sealant material) may be positioned on the carrier such that it contacts at least a portion of the inner surface. The edge portion may be free of any sealant material.

The carrier may comprise an edge portion surrounding an inner portion of the carrier. More specifically, the edge portion may include an outwardly projecting ledge (ridge). The edge portion may be connected to the inner portion along a barrier wall, which may extend substantially around the inner portion or may extend only partially around the inner portion. One or more of the edge portion, the outwardly projecting ledge, and the blocking wall may be free of any additional extensions.

Fasteners may be included that are formed integrally with the carrier or separately from the carrier. The fastening means may extend from the edge portion. The fastening means may be located in a different plane than the inner portion of the carrier or may be located in the same plane as the inner portion of the carrier. The fastening means may extend substantially parallel to the inner portion of the carrier or may extend substantially perpendicular to the inner portion of the carrier. The fastening means may extend at an oblique angle with respect to the inner portion of the carrier. Fastening means may include arrow fasteners, tree fasteners, clips, hooks, and the like. The fastening means may comprise an opening for receiving the extension from within the cavity in which the baffle assembly is located. The fastening means may be provided as a magnetic or adhesive material that may attach (e.g., adhere or magnetically secure) the baffle assembly to the cavity. In such embodiments, the magnetic material or the adhesive material may be dispersed within the carrier or the second material. Alternatively, the magnetic material or the adhesive material may be provided on or otherwise attached to the carrier and/or the second material.

The baffle assembly may be substantially free of any structure on the carrier for preventing the second material from flowing onto the edge portion of the carrier. Certain portions of the carrier may be substantially free of any structure for securing the second material to the carrier. As an example, the inner portion may be substantially free of any structural members for securing the second material to the carrier. The barrier wall may be substantially free of any structural members for securing the second material to the carrier.

The formation of the material of the present teachings may include various processing steps depending on the desired configuration of the material. Various processes such as molding (e.g., compression, injection, or other molding), extrusion, etc., may be used to form the carrier material and the second material. The carrier and the second material may be formed by a multiple injection molding process.

The size and shape of the baffle assembly may depend on the desired location of the device within the cavity. The edge portion of the baffle assembly may be shaped such that it fits within and conforms to the cross-section of the cavity. The baffle assembly may be shaped such that, where the second material is an expandable material, the expandable material expands directly to a region that is traditionally difficult to access (e.g., a small region within the cavity that is difficult to seal due to the size and shape of the region). The second material may be located on the inner portion such that the second material may be activated to expand over and on the inner portion. The baffle assembly may be positioned within the cavity with the one or more fasteners such that the edge portion of the baffle assembly does not contact the cavity wall prior to expansion of the second material.

The baffle assembly may include one or more openings along an interior portion of the carrier. The second material may expand to cover the one or more openings. Alternatively, the baffle assembly may include an edge, slot or attachment that guides the second material to expand and thus prevents the second material from covering the one or more openings. One or more openings may be present so that fluid (e.g., e-coating fluid) may drain from one side of the baffle assembly to the other before the second material expands. The one or more openings may allow the device or material within the cavity to pass from one side of the baffle assembly to the other side of the baffle assembly before or after the second material expands. As an example, one or more openings may allow a drain to pass through. The one or more openings may also provide access points within the cavity for welding purposes.

The carrier may comprise a rigid polymeric material. The carrier may comprise a flat metal plate. The carrier may also comprise a mesh material. The carrier may comprise a variety of other materials, such as polymers, elastomers, fibrous materials (e.g., cloth or woven materials), thermoplastics, plastics, nylons, and combinations thereof. The carrier may be flexible to allow the baffle assembly to bend to fit within the desired small space of the cavity.

After placing the baffle assembly into the cavity, the second material may be an activatable material that expands according to a predetermined set of conditions. For example, exposure to a certain level of heat may cause the second material to expand. The volumetric expansion of the second material may vary depending on the sealing and/or baffling requirements of a particular cavity. The second material may expand by at least about 100%. The second material may expand less than about 2000%. The second material may expand at least about 500%, at least about 1000% or more. The second material may expand less than about 1000% or even less than about 500%.

The second material may be resinous, generally dry or tacky to the touch, and may be shaped in any form of desired pattern, location or thickness, but preferably has a substantially uniform thickness. Although other heat-activated materials may be used for the second material, preferred heat-activated materials are expandable polymers or plastics, and are preferably foamable. The second material may be a relatively high expansion foam having a polymer formulation including one or more of an epoxy resin, an acetate (e.g., ethylene vinyl acetate), a thermoplastic polyether, an acrylate and/or methacrylate (e.g., a copolymer of butyl acrylate and methyl acrylate), an epoxy/elastomer adduct, and one or more fillers (e.g., clay fillers and/or nanoparticle-containing fillers). Preferred thermally expandable materials are described in U.S. patent nos. 7,313,865; 7,125,461, respectively; and 7,199,165, which are incorporated herein by reference for all purposes. For example, but not limited to, the foam may also be an EVA/rubber based material, including ethylene copolymers or terpolymers, possibly with an alpha-olefin. As a copolymer or terpolymer, a polymer is composed of two or three different monomers, i.e., small molecules with high chemical reactivity that can be attached to similar molecules. Suitable swellable materials include those available from L & L products under the designations L7220, L2821, L1066, L205, L2010, L2105, L2108A, L2806, L2811, L4200, L4141, L4161, L4315, L5510, L5520, L5540, L5600, L5601, L7102 and L7104.

The expandable material may be formed of other materials, provided that the selected material is heat activated or otherwise activated by ambient conditions (e.g., humidity, pressure, time, etc.) and cured under suitable conditions for the selected application. One such material is the epoxy-based resin disclosed in U.S. Pat. No. 6,131,897, the teachings of which are incorporated herein by reference. Some other possible materials include, but are not limited to, polyolefin materials, copolymers and terpolymers with at least one monomer type being an alpha-olefin, phenol/formaldehyde materials, phenoxy materials, and polyurethane materials with high glass transition temperatures. Additional materials may also be used, such as U.S. patent No. 5,766,719; 5,755, 486; 5,575,526, respectively; and 5,932,680, which are incorporated herein by reference for all purposes.

In applications where the expandable material is a heat activated material, important considerations relating to the selection and formulation of the material are the curing temperature of the material and, if expandable, the expansion temperature. Typically, for example, during a coating (e.g., electronic coating, paint, or varnish) curing step, when the material is processed at high temperatures or higher application levels with automotive structures, the material may become active (cure, swell, or both) at higher processing temperatures, such as those encountered at automotive assembly plants. For body shop applications (e.g., e-coating) as well as paint shop applications, the temperatures encountered in automotive assembly operations may range from about 148.89 ℃ to 204.44 ℃ (about 300 ° F to 400 ° F), typically about 93.33 ℃ (about 200 ° F) or slightly higher (e.g., 120 ℃ to 150 ℃).

The baffle assembly of the present teachings may be installed in an automobile, although it may also be used with other articles of manufacture, such as boats, buildings, furniture, storage containers, and the like. The baffle assembly may be used to seal and/or baffle various components of an automobile, including, but not limited to, body components (e.g., panels), frame components (e.g., hydroformed tubes), pillar structures (e.g., a-pillar, B-pillar, C-pillar, or D-pillar), bumpers, roofs, bulkheads, instrument panels, wheel wells, floor pans, door beams, hem flanges, vehicle beltline applications, doors, rocker arms, trunk lids, hoods, and the like of an automobile.

Fig. 1-3 illustrate a baffle assembly 10 having a carrier 12 including an inner portion 14, an edge portion 16, and a fastener 18 and including a layer of resin material 20 thereon. Fig. 4 shows the baffle assembly 10 in use in a vehicle cavity 22.

Any numerical value recited herein includes all values from the lower value to the upper value in increments of one unit provided that there is a separation of at least 2 units between any lower value and any upper value. As an example, if values of quantities of components or process variables, such as, for example, temperature, pressure, time, etc., are stated, for example, from 1 to 90, preferably from 20 to 80, more preferably from 30 to 70, it is intended that values such as 15 to 85, 22 to 68, 43 to 51, 30 to 32, etc., are expressly enumerated in this specification. For values less than one, one unit is considered to be 0.0001, 0.001, 0.01, or 0.1, as appropriate. These are only examples of what is specifically intended, and all possible combinations of numerical values between the lowest value and the highest value enumerated, are to be considered to be expressly stated in this application in a similar manner. It can be seen that the teaching herein of amounts expressed in "parts by weight" also contemplates the same ranges expressed in weight percent. Thus, the teaching of ranges for "parts by weight of 'x' of the resulting polymer blend component" in embodiments of the invention also contemplates ranges for the same recited amounts expressed as "weight percent of 'x' of the resulting polymer blend component".

Unless otherwise indicated, all ranges include both endpoints and all numbers between endpoints. The use of "about" or "approximately" with respect to a range applies to both ends of the range. Thus, "about 20 to 30" is intended to encompass "about 20 to about 30," including at least the endpoints specified.

All articles and references of the present disclosure, including patent applications and publications, are incorporated herein by reference for all purposes. The term "consisting essentially of … …" when used to describe a combination is intended to include the identified elements, components, or steps, as well as such other elements, components, or steps, which do not materially affect the basic and novel characteristics of the combination. The terms "comprising" or "including" as used herein to describe combinations of elements, ingredients, components or steps also contemplate embodiments that consist essentially of the elements, ingredients, components or steps. By using the term "may" herein, it is meant that any described attribute that "may" be included is optional.

A plurality of elements, components, groups or steps may be provided by a single integrated element, component, group or step. Alternatively, a single integrated element, ingredient, component or step may be divided into separate plural elements, ingredients, components or steps. The disclosure of "a" or "an" to describe an element, ingredient, component or step is not intended to exclude additional elements, ingredients, components or steps.

It is to be understood that the above description is intended to be illustrative, and not restrictive. Many embodiments and many applications other than the examples provided will be apparent to those of skill in the art upon reading the above description. The scope of the invention should, therefore, be determined not with reference to the above description, but instead should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. All articles and references of the present disclosure, including patent applications and publications, are incorporated herein by reference for all purposes. The omission in the following claims of any aspect of subject matter disclosed herein is not a disclaimer of such subject matter, nor should it be construed that the inventors do not consider such subject matter as part of the disclosed inventive subject matter.