Baffle Reinforcement Element With Bendable Tabs For Manual Assembly
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Solution Overview
Problem
Existing methods for sealing and reinforcing automotive vehicle cavities are complex and require expensive tooling and machinery, making them costly and impractical for low-volume production or low-labor-cost regions.
Innovation Solution
A baffle or reinforcement element comprising a carrier element with bendable tabs that connect an expandable foam element, allowing for manual assembly without expensive machinery, using a sandwich structure with a cover element and a form-fit or force-fit connection to secure the expandable element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If pins and fastening methods are used to connect carrier and support plate, then connection strength is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent removes the complex pin fastening system and support plate structure, extracting only the essential connection function. The carrier is directly attached to the cavity wall using simple attachment means such as clips or adhesive, eliminating unnecessary components while maintaining connection strength.
Solution Approach 2:
The patent employs simple, inexpensive attachment means like clips or adhesive that can be easily applied and removed, replacing expensive and complex pin fastening systems. These attachment means are designed for ease of manufacture and installation, reducing overall device complexity.
2Manufacturing precision
If complex tooling and machinery are used for assembly, then manufacturing precision is improved, but production cost increases
Solution Approach 1:
The patent divides the assembly into simple, modular components (carrier, expandable element, attachment means) that can be manufactured separately using simple tools and assembled manually. This segmentation allows each component to be produced with basic equipment while maintaining overall assembly precision through simple connection geometries.
Solution Approach 2:
The attachment means are designed to self-align and self-secure during manual assembly, eliminating the need for complex positioning tools or machinery. The simple geometric features of the attachment means guide proper alignment and secure the components without requiring precision tooling.
3Ease of manufacture
If standardized expandable components are used, then ease of manufacture is improved, but connection reliability may worsen
Solution Approach 1:
The patent applies different connection strategies at different locations: standardized expandable elements are used in regions where simple attachment is sufficient, while localized reinforcement or specialized attachment means are applied at critical connection points. This ensures both cost-effectiveness through standardization and reliability at critical interfaces.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables a simple, cost-effective assembly of the baffle or reinforcement element, reducing production costs and tooling investment, while maintaining structural stability and efficiency in sealing or reinforcing automotive vehicle cavities.
Implementation Method 1
an expandable element, in particular foam element, supported by the carrier element
Implementation Method 2
The foamable material is arranged within the gap. In an embodiment, an attachment means comprises a clip
Data Source
Figure 1~2
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Figure 6~8
AI summary
A baffle or reinforcement element for sealing and/or reinforcing a cavity, in particular a cavity of a vehicle, comprising a carrier element (18) and an expandable element (12) supported by the carrier element (18), and connection means including a plurality of tabs (10) provided on the carrier element (18), for connecting the carrier element (18) and the expandable element (12).