Baffle / reinforcement insert with directional expansion seal (DES) and method of making same

Abstract

A baffle assembly for use in a cavity, the baffle assembly comprising a first substrate; a second substrate; and an activatable adhesive layer, the activatable adhesive layer being disposed between the inner first surface and the inner second surface; and a snap member disposed on the exposed surface of the first substrate or the second substrate, adapted to hold the first substrate, the second substrate and the adhesive layer together prior to activation of the adhesive, and adapted to hold the baffle assembly in the cavity.

Description

TECHNICAL FIELD

[0001] The present teachings generally relate to an insert for use in a vehicle frame, and more particularly to a unique insert assembly having a deflection sealing (DES) baffle / stiffener insert and a method of manufacturing the same in a sandwich construction. BACKGROUND

[0002] Vehicles can have relatively long spans in the chassis frame or body-in-white (BIW) that can require additional support and / or baffle inserts. It is well known that excessive tooling costs can be particularly concerning for vehicles having relatively low annual sales (e.g., annual sales of less than about 40,000 vehicles). It has been recognized that it is desirable to minimize tooling costs for many items such as baffle / stiffeners while still maintaining performance (e.g., weight, durability, stiffness, etc.) for low sales vehicles. It has also been recognized that it can be desirable to control the flow of any adhesive in the system, especially for expandable adhesives. SUMMARY

[0003] The present teachings satisfy one or more of the above-described needs with the improved insert assembly and method described herein.

[0004] In one aspect, the present teachings relate to a baffle assembly for use in a cavity, comprising: a first substrate comprising an exposed first surface, an interior first surface, and a first thickness therebetween; a second substrate comprising an exposed second surface, an interior second surface, and a second thickness therebetween; a layer of activatable adhesive disposed between the interior first surface and the interior second surface; and a snap member disposed on the exposed surface of the first substrate or the second substrate, adapted to hold the first substrate, the second substrate, and the adhesive layer together prior to activation of the adhesive, and adapted to hold the baffle assembly in the cavity.

[0005] In another aspect, the teachings herein relate to one or more aspects of the assemblies as described above, wherein the snap member includes an engagement feature adapted to secure the second component to the baffle assembly; wherein the second component is a second baffle assembly; wherein at least one of the first substrate, the second substrate, or the adhesive layer includes a partial through hole; wherein the first substrate, the second substrate, or both include one or more holes to allow fluid flow between the respective exposed second surfaces prior to or after the adhesive layer is activated; wherein the snap member includes at least one anti-rotation feature; wherein the first substrate, the second substrate, or both are comprised of a polymeric material; wherein the first substrate, the second substrate, or both are comprised of a paper material; wherein the adhesive layer is comprised of an expandable adhesive material; wherein the expandable adhesive flows outward from the peripheral edges of the first substrate and the second substrate only, toward the walls of the cavity; wherein the first substrate, the second substrate, or both include at least one through hole to allow the expandable adhesive to flow through during the activation process; wherein the adhesive layer is a multi-layer adhesive assembly including at least two (2) different adhesive compositions or layers; wherein the at least two (2) different adhesive compositions or layers include a first adhesive layer comprised of an expandable adhesive material and a second layer comprised of a structural adhesive material; wherein the adhesive layer is a multi-layer adhesive and substrate assembly including at least three (3) different adhesive layers and an additional substrate layer; wherein the first substrate, the second substrate, or both include a multi-layer substrate assembly including at least two (2) different substrate compositions or layers; wherein the at least two (2) different substrate compositions or layers include a first polymeric layer comprised of a nylon material and a second layer comprised of a paper material; wherein the nylon material is reinforced with fibers and the paper material is flat sheet stock or corrugated cardboard.

[0006] In a second aspect, the teachings relate to a method of manufacturing an assembly (as described herein), the method comprising: a method of manufacturing a baffle assembly for use in a cavity, the method comprising the steps of: providing a first substrate comprising an exposed first surface, an interior first surface, and a first thickness therebetween; providing a second substrate comprising an exposed second surface, an interior second surface, and a second thickness therebetween; providing an activatable adhesive layer; providing a snap member adapted to retain the assembled baffle assembly within the cavity; laying the adhesive layer on the interior first surface of the first substrate; laying the second substrate onto the adhesive layer, opposite the first substrate; laying on the interior second surface to form a baffle subassembly; cutting the baffle subassembly into a desired shape, the desired shape comprising at least one hole for receiving a portion of the snap member; assembling the snap member to the baffle subassembly to complete the baffle assembly.

[0007] In another aspect, the teachings herein relate to one or more aspects of the manufacture of an insert assembly as described above, wherein the step of cutting into a desired shape occurs prior to providing the first substrate and the second substrate and the adhesive layer; wherein at least one of the provided first substrate, the second substrate, and the adhesive layer is in a roll, and the laying step occurs in a continuous process; it further comprises the step of providing a multi-layer adhesive assembly for the adhesive layer; wherein the cutting step is performed by a cutting process selected from one or more of a die cutting tool, a water jet cutter, or a laser cutter. BRIEF DESCRIPTION OF DRAWINGS

[0008] Figure 1 is a perspective view of an exemplary vehicle according to the present invention.

[0009] Figure 2 is a perspective view of an exemplary fender / reinforcement insert having a directional expansion seal according to the present invention.

[0010] Figure 3 is a perspective view of an exemplary fender / reinforcement insert having an additional connection insert according to the present invention.

[0011] Figure 4 is a perspective view of another exemplary fender / reinforcement insert having a directional expansion seal according to the present invention.

[0012] Figure 5 is Figure 3 insert in situ of section A-A of Figure 1 is a top view of

[0013] Figure 6 is Figure 5 is a bottom view of

[0014] Figure 7 is a perspective view of an exemplary fender / reinforcement insert subassembly.

[0015] Figure 8 is Figure 7 is an exploded view of the subassembly of

[0016] Figure 9 is a perspective view of an exemplary buckle member according to the present invention.

[0017] Figure 10 is a schematic view of an exemplary manufacturing line according to the present invention. DETAILED DESCRIPTION

[0018] The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the application, its principles, and its practical application. Those skilled in the art are readily able to adapt the

[0019] The teachings herein can generally relate to an inventive baffle insert assembly for use in cavities of structural frame assemblies (in automotive chassis or BIW). The inventive reinforcement insert assembly includes a slightly flat, multi-layer baffle having a snap member that facilitates securing the assembly into the cavity and holding the layers of the assembly together (at least until the adhesive layer is activated).

[0020] Vehicle frame assembly (chassis or BIW) 20

[0021] Vehicle Frame The assemblies 20 generally include a frame cavity 22 having an inner frame wall 24 and an outer frame wall 26. These assemblies 20 can be part of a vehicle chassis frame, or as part of a body-in-white. These can be formed from a variety of materials. The frame members can have certain members formed from one material and other frame members formed from a second material. The frame assemblies can be formed from a polymeric material (e.g., polyurethane, polyamide, polypropylene), a metallic material (e.g., aluminum, steel, magnesium), a fibrous material (glass fiber, carbon fiber, aramid fiber), or some combination of these materials. Where the assemblies 20 (or baffle assemblies 30) utilize an adhesive, the adhesive can be an acrylate-based adhesive, an epoxy-based adhesive, a polyurethane-based adhesive, a polyimide-based adhesive, or some combination thereof. The adhesive can be a one- or two-component reactive adhesive. The adhesive can be in the form of a film or tape. The adhesive can be a hot melt adhesive. The adhesive can be a foamed adhesive. The adhesive can be activated (e.g., to cure, foam, adhere, etc.) by stimulus. The adhesive can be activated due to the combination of two components. The adhesive can be further detailed and described in the following sections.

[0022] Baffle assembly 30 - general description

[0023] The focus of the present invention is a fender assembly 30 having three or more layers (40, 50, 60) including at least one adhesive layer 50, a first substrate layer 40, a second substrate layer 60, and a clip member 70 that connects the layers 40, 50, 60 together and to the vehicle frame assembly 20. It is contemplated that the fender assembly 30 is used to at least provide some degree of partial sealing and / or reinforcement to the frame assembly 20. It is contemplated that the use of a third layer (whether polymeric or paperboard) also has the benefit of protecting the adhesive layer during storage / transport. It is also contemplated that the fender assembly 30 can include a second, third, or more additional components 36 connected together by clip connection members 72 that facilitate the joining of one clip member 70 to another. It is contemplated that the additional components 36 can be another fender assembly 30 or fender subassembly 34 or something different such as an expandable foam block. It is also contemplated that the fender assembly 30 can include additional substrate layers and / or additional adhesive layers. It is contemplated that the substrate layers are generally flat / planar and provide some degree of directional control for any expansion of the adhesive layer 50. It is contemplated that the use of a layer on each side of the adhesive layer 50 (whether polymeric or paperboard) also has the benefit of protecting the expandable adhesive layer during storage / transport. The fender assembly 30 of the present invention can be installed in a motor vehicle, but can also be used in other manufactured items such as watercraft, buildings, furniture, storage containers, etc. The fender can be used to seal and / or block a variety of components of a motor vehicle including, but not limited to, body components (e.g., panels) of a motor vehicle, frame components (e.g., hydroformed tubes), pillar structures (e.g., A-pillar, B-pillar, C-pillar, or D-pillar), bumpers, roofs, bulkheads, dashboards, wheel wells, floors, door beams, flange hem flanges, vehicle beltline applications, doors, rocker panels, rocker beams, decklids, hoods, etc. Each of the various components of the assembly 30 are described in further detail in the subsequent paragraphs.

[0024] First substrate layer 40

[0025] It is contemplated that the first substrate layer 40 and the second substrate layer 60 can be duplicates of one another, or can be completely different, and can be interchanged in the assembly 30. The first substrate layer 40 serves as an outer wall of the assembly 30 (exposed first surface 42), provides a surface on which the adhesive layer is located (inner first surface 44), and has a first wall thickness 46 between these two surfaces. The first substrate layer 40 can be composed of a single layer of material or a combination of materials, but is preferably a generally flat sheet of material that can be used for one wall of the assembly 30. It is contemplated that the layer 40 is a flat blank, which can be in the form of a pre-formed part, a part cut from a sheet, or a part cut from a roll. In a preferred embodiment, the layer 40 is in sheet or roll form to minimize the tooling required for the entire assembly 30. Preferred compositions include polymeric materials such as nylon, fiber-filled nylon, thermoplastics, thermosets, and any polymeric material having a melting point above about 200 degrees Celsius. It can also preferably be composed of natural materials such as paper or cardboard. The first thickness 46 can be as small as 0.1 mm or as large as 20 mm, preferably in the range of about 0.5 mm to 10 mm, and more preferably in the range of about 1 mm to 5 mm. The first substrate 40 can have a shape that is complementary to the shape of the frame cavity 22 in which it will be placed. It can include one or more through holes to facilitate attachment of one or more attachment features of the clip member 70. In a preferred embodiment, there are no additional through holes in the exposed surface 42 so that adhesive can only flow (or swell) from the peripheral edge 32 of the assembly 30. It can also include holes 80 that allow a portion of the adhesive layer 50 to be exposed to the rest of the frame cavity 22, and depending on any swelling of the adhesive used, these holes can assist in holding the layers together, for example, in the event that the adhesive swells and mushrooms through the thickness 46 and to the exposed surface 42, as shown in Figure 6

[0026] Second substrate layer 60

[0027] ​As noted above, it is contemplated that the first substrate layer 40 and the second substrate layer 60 can be duplicates of one another, or can be entirely different, and can be interchanged in the assembly 30. The second substrate layer 60 serves as an outer wall of the assembly 30 (exposed second surface 62), provides a surface upon which the adhesive layer is located (inner second surface 64), and has a second wall thickness 66 between these two surfaces. Like the first substrate layer 40, the second substrate layer 60 can be comprised of a single layer of material or a combination of materials, but is preferably a generally flat sheet of material that can be used for one wall of the assembly 30. It is contemplated that the layer 60 is a flat blank, which can be in the form of a pre-formed part, a part cut from a sheet, or a part cut from a roll. In a preferred embodiment, the layer 60 is in sheet or roll form to minimize the tooling required for the overall assembly 30. Preferred compositions include polymeric materials such as nylon, fiber-filled nylon, thermoplastics, thermosets, and any polymeric material having a melting point above about 200 degrees Celsius. In situations where the assembly 30 can be subjected to lower bake temperatures, it is possible and preferred to utilize polymeric materials having a melting point below about 200 degrees Celsius such as polycarbonate / acrylonitrile butadiene styrene, acrylonitrile butadiene styrene, and polypropylene. It can also be preferred to be comprised of natural materials such as paper or cardboard. The second thickness 66 can be as small as 0.1 mm or as large as 20 mm, preferably in the range of about 0.5 mm to 10 mm, and more preferably in the range of about 1 mm to 5 mm. The second substrate 60 can have a shape that is complementary to the shape of the frame cavity 22 into which it will be placed. It can include one or more through holes to facilitate attachment of one or more attachment features of the snap member 70. It is also contemplated that the snap member 70 is provided on the exposed second surface 62. In a preferred embodiment, there are no additional through holes 80 in the exposed surface 62 such that the adhesive can only flow (or swell) from the peripheral edge 32 of the assembly 30 (or through holes 80 in the layers 40, 60), also known as directional expansion sealing (DES). It can also include holes 80 that allow a portion of the adhesive layer 50 to be exposed to the remainder of the frame cavity 22, and depending on any swelling of the adhesive used, these holes can assist in securing the layers together, for example, in the event that the adhesive swells and mushrooms through the thickness 66 and to the exposed surface 62, as shown in Figure 6

[0028] Snap member 70

[0029] ​The substrates 40, 60 and the adhesive layer 50 may require one or more components (e.g., snap-fit ​​member 70) to hold the layers (40, 50, 60) in place / together, at least temporarily, until the adhesive is activated in the assembly 30. Additionally, member 70 can be used for adhesion to the second baffle assembly 30 and / or to a portion of the frame cavity 22. In this invention, the preferred manner in which this function is provided is via snap-fit ​​member 70 having the following structural components. As an illustrative example, see reference... Figure 2 and Figure 3 The snap-fit ​​member 70 is envisioned to have one or more snap-fit ​​connecting members 72, which have the dual function of holding layers 40, 50, and 60 together (either as a post with locking washers 75 or as a Christmas tree-shaped structure not shown) and providing an optional means of attaching the second baffle assembly 30 to the first baffle assembly. Additionally, the snap-fit ​​member 70 includes a cavity connecting member 74 that provides means of connecting the baffle assembly 30 to or through the wall of the frame cavity 22. In the illustrative example shown in the figures, the cavity connecting member 74 may be in the form of a Christmas tree-shaped snap. In a preferred embodiment, the snap-fit ​​member 70 is at least partially symmetrical about a central axis 76, such that it can be used for both baffle assemblies 30 on the right or left side of the vehicle 10. It is also envisioned that the snap-fit ​​member includes one or more anti-rotation legs 78, examples of which can be seen in the figures.

[0030] Adhesive layer 50

[0031] The adhesive material may be a two-component material that is activated when the two components are combined (e.g., cured, foamed, or some combination thereof). Activation may occur at room temperature or at an elevated activation temperature. It is also conceivable that the adhesive layer is a multilayer adhesive assembly comprising at least two (2) different adhesive compositions or layers, for example, one composition being an expandable adhesive having a first expansion value, and the second being an expandable adhesive having a different second expansion value. It is also conceivable that the second adhesive material is a non-expandable structural adhesive and may contribute to the structure and stiffness of the assembly 30.

[0032] It is envisioned and preferred that the adhesive material used in the adhesive layer is an expandable sealing material, more specifically, an expandable material that expands upon application of heat or energy. After the baffle is placed into the cavity, the expandable sealing material can expand according to a predetermined set of conditions. For example, exposure to a certain level of heat can cause the expandable material to expand. The volume expansion of the expandable material can vary depending on the sealing and / or blocking requirements of a particular cavity. The expandable material can expand to fill vehicle cavities and cover voids in the internal body of the vehicle. The expandable material can expand by at least about 100%. The expandable material can expand by less than about 2000%. The expandable material can expand by at least about 500%, at least about 1000%, or more. The expandable material can expand by less than about 1000% or even less than about 500%. The adhesive material may be an epoxy-based material, such as those disclosed in U.S. Patent Nos. 5,884,960; 6,348,513; 6,368,438; 6,811,864; 7,249,415 and U.S. Patent Publication No. 2004 / 0076831, the entire contents of which are incorporated herein by reference for all purposes. The adhesive may include one or more phosphate ester-based components, such as those disclosed in U.S. Patent No. 10,550,220, the entire contents of which are incorporated herein by reference for all purposes. Expandable sealants can generally be touch-dry or tacky and can be shaped in any desired pattern, arrangement, or thickness, but preferably have a substantially uniform thickness. While other thermally activated materials are possible for expandable sealants, the preferred thermally activated materials are expandable polymers or plastics, and more preferably foamable thermally activated materials. Expandable sealing materials can be relatively high-expansion foam materials whose polymer formulations include one or more of epoxy resins, acetates (e.g., ethylene vinyl acetate), thermoplastic polyethers, acrylates and / or methacrylates (e.g., copolymers of butyl acrylate and methyl acrylate), epoxy / elastomer adducts, and one or more fillers (e.g., clay fillers and / or nanoparticle-containing fillers). Preferred thermally expandable materials are disclosed in U.S. Patent Nos. 7,313,865; 7,125,461; and 7,199,165, which are incorporated herein by reference for all purposes. For example, but not limited to, the foam material can also be an EVA / rubber-based material, including ethylene copolymers or terpolymers that may have α-olefins. As copolymers or terpolymers, the polymer consists of two or three different monomers, i.e., small molecules with high chemical reactivity that can be linked to similar molecules.Suitable expandable materials include those available from L&L Products, Inc., model numbers L7220, L2821, L1066, L205, L2010, L2105, L2108A, L2806, L2811, L4200, L4141, L4161, L4315, L5510, L5520, L5540, L5600, L5601, L7102, and L7104. The expandable material can be in the form of die-cut extruded sheets or rolls. In a preferred embodiment, the adhesive layer 50 is similar in shape (e.g., peripheral shape) to the first substrate member 40, the second substrate member 60, or both.

[0033] Manufacturing method

[0034] An important aspect of the present invention is envisioned as the ability to manufacture the baffle assembly 30 as described above with minimal tooling and a simple process. An exemplary manufacturing line 100 can be used... Figure 10 As seen in the image, the method envisions comprising the following steps: providing a first substrate in sheet form, comprising an exposed first surface 42, an inner first surface 44, and a first thickness 46 therebetween; providing a second substrate 60 in sheet form, comprising an exposed second surface 62, an inner second surface 64, and a second thickness 66 therebetween; providing an adhesive layer 50 in sheet form that can be activated; providing a snap-fit ​​member 70 adapted to hold layers 40, 50, and 60 together and to hold the assembled baffle assembly 30 in a cavity; laying the adhesive layer 50 on the inner first surface 44 of the first substrate 40; laying the second substrate 60 onto the adhesive layer 50 opposite to the first substrate 40; laying on the inner second surface to form a baffle subassembly 34; cutting the baffle subassembly into a desired shape, the desired shape including at least one through-hole 80 for receiving a portion of the snap-fit ​​member 70; and assembling the snap-fit ​​member 70 onto the baffle subassembly 34 to complete the baffle assembly 30. It is also conceivable that the step of cutting into the desired shape occurs before providing the first substrate 40, the second substrate 60, and the adhesive layer 50. It is also possible that at least one of the provided first substrate 40, second substrate 60, and adhesive layer 50 is in rolls, and the lay-up step is performed as a continuous process. It is also conceivable that the process includes providing a multilayer adhesive assembly for the adhesive layer, and the cutting step is performed using a cutting process selected from one or more of die-cutting tools, waterjet cutting machines, or laser cutting machines.

[0035] Unless otherwise stated, the dimensions and geometries of the various structures described herein are not intended to limit the invention, and other dimensions or geometries are possible. Multiple structural components may be provided by a single integrated structure. Alternatively, a single integrated structure may be divided into multiple separate components. Furthermore, while features of the invention may have been described in the context of only one of the illustrated embodiments, such features may be combined with one or more other features of other embodiments for any given application. It will also be understood from the foregoing that the manufacture and operation of the unique structures described herein also constitute a method according to the invention.

[0036] Preferred embodiments of the present invention have been disclosed. However, those skilled in the art will recognize that certain modifications will fall within the teachings of this invention. Therefore, the following claims should be studied to determine the true scope and content of the invention.

[0037] The explanations and descriptions provided herein are intended to familiarize others skilled in the art with the invention, its principles, and its practical applications. Those skilled in the art can modify and apply the invention in various forms, as best suited to the requirements of a particular application. Therefore, the specific embodiments of the invention set forth are not intended to be exhaustive or limiting. Consequently, the scope of the invention should not be determined by reference to the above description, but rather by reference to the appended claims and the full scope of their equivalents. The disclosure of all articles and references (including patent applications and publications) is incorporated herein by reference for all purposes. Other combinations are also possible, as obtained from the following claims, which are also incorporated herein by reference.

[0038] Element number

[0039] 10 vehicles

[0040] 20 Vehicle frame components

[0041] 22 Frame cavity

[0042] 24 Internal frame wall

[0043] 26. External frame wall

[0044] 30 baffle assembly

[0045] 32. Outer edge

[0046] 34 Baffle Subassemblies

[0047] 36 Additional Components

[0048] 40 First base material component

[0049] 42 Exposed first surface 44 Internal first surface

[0050] 46 First wall thickness

[0051] 50 adhesive layers

[0052] 60 Second base material component

[0053] 62 Exposed second surface 64 Internal second surface

[0054] 66 Second wall thickness

[0055] 70 Clip-on components

[0056] 72 Snap-fit ​​connection components

[0057] 74 Cavity connecting components

[0058] 75 Locking Washer

[0059] 76 Central Axis

[0060] 78 Anti-rotation outriggers

[0061] 80 through hole

[0062] 100 manufacturing lines

Claims

1. A baffle assembly for use in a cavity, comprising: A first substrate, the first substrate including an exposed first surface, an inner first surface, and a first thickness between the exposed first surface and the inner first surface; The second substrate, wherein the first substrate includes an exposed second surface, an inner second surface, and a second thickness between the exposed second surface and the inner second surface; An activatable adhesive layer is disposed between the inner first surface and the inner second surface; as well as A snap-fit ​​member disposed on an exposed surface of the first substrate or the second substrate, adapted to hold the first substrate, the second substrate and the adhesive layer together prior to adhesive activation, and adapted to hold the baffle assembly in the cavity.

2. The baffle assembly of claim 1, wherein the snap-fit ​​member includes engagement features adapted to secure the second component to the baffle assembly.

3. The baffle assembly according to claim 2, wherein the second component is a second baffle assembly.

4. The baffle assembly of claim 1, wherein at least one of the first substrate, the second substrate, or the adhesive layer includes a partial through-hole.

5. The baffle assembly of claim 1, wherein the first substrate, the second substrate, or both comprise one or more pores to allow fluid to flow between the respective exposed second surfaces before or after the adhesive layer is activated.

6. The baffle assembly of claim 1, wherein the snap-fit ​​member includes at least one anti-rotation feature.

7. The baffle assembly of claim 1, wherein the first substrate, the second substrate, or both are made of a polymer material.

8. The baffle assembly of claim 1, wherein the first substrate, the second substrate, or both are made of paper material.

9. The baffle assembly of claim 1, wherein the adhesive layer is made of an expandable adhesive material.

10. The baffle assembly of claim 9, wherein the expandable adhesive flows only from the peripheral edges of the first substrate and the second substrate outward toward the wall of the cavity.

11. The baffle assembly of claim 9, wherein the first substrate, the second substrate, or both include at least one through-hole to allow the expandable adhesive to flow through during the activation process.

12. The baffle assembly according to claim 1, wherein the adhesive layer is a multilayer adhesive assembly comprising at least two (2) different adhesive compositions or layers.

13. The baffle assembly of claim 12, wherein the at least two (2) different adhesive compositions or layers comprise a first adhesive layer composed of an expandable adhesive material and a second layer composed of a structural adhesive material.

14. The baffle assembly of claim 1, wherein the adhesive layer is a multilayer adhesive and substrate assembly comprising at least three (3) different adhesive layers and an additional substrate layer.

15. The baffle assembly of claim 1, wherein the first substrate, the second substrate, or both comprise a multilayer substrate assembly comprising at least two (2) different substrate compositions or layers.

16. The baffle assembly of claim 15, wherein the at least two (2) different substrate compositions or layers comprise a first polymer layer of nylon material and a second layer of paper material.

17. The baffle assembly of claim 16, wherein the nylon material is reinforced with fibers, and the paper material is flat paper or corrugated cardboard.

18. A method of manufacturing a baffle assembly for use in a cavity, the method comprising the steps of: a. Providing a first substrate, the first substrate including an exposed first surface, an inner first surface, and a first thickness between the exposed first surface and the inner first surface; b. Providing a second substrate, the second substrate including an exposed second surface, an inner second surface, and a second thickness between the exposed second surface and the inner second surface; c. Provides an activatable adhesive layer; d. Provide a snap-fit ​​member adapted to retain the assembled baffle assembly in the cavity; e. Lay the adhesive layer on the inner first surface of the first substrate; f. Lay the second substrate onto the adhesive layer, opposite to the first substrate; The baffle sub-assembly is laid on the inner second surface to form a baffle sub-assembly. g. Cut the baffle subassembly into a desired shape, the desired shape including at least one hole for receiving a portion of the snap-fit ​​member; h. Assemble the snap-fit ​​component onto the baffle subassembly to complete the baffle assembly.

19. The method of claim 18, wherein the step of cutting into the desired shape occurs before providing the first substrate and the second substrate and the adhesive layer.

20. The method of claim 18, wherein at least one of the provided first substrate, second substrate and adhesive layer is in roll form, and the laying step is performed as a continuous process.

21. The method of claim 18, further comprising the step of providing a multilayer adhesive assembly for the adhesive layer.

22. The method of claim 18, wherein the cutting step is performed by a cutting process selected from one or more of a die-cutting tool, a waterjet cutter, or a laser cutter.

Images