Baffle Reinforcement Reverse Molding Tooling

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Solution Overview

Problem

Existing methods for forming baffles or reinforcements with thermally expandable materials for acoustic dampening and structural reinforcement in automotive and aerospace applications are costly due to high tooling expenses, while also requiring improvements in acoustic and sealing performance.

Innovation Solution

A tooling system with a mold and a selectively rotatable plate that moves expandable material from one cavity to another, allowing for overmolding of a carrier material to form a baffle or reinforcement, reducing tooling costs and enhancing bonding through chemical adhesion without mechanical fittings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional techniques such as extruding, overmolding, or assembling separately produced components are used, then suitable baffles or reinforcements can be produced, but tooling cost increases

Engineering Contradiction:

Improveacoustic and sealing performanceVSAvoidtooling cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines the molding of the carrier and the expandable material into a single integrated tooling process. The mold includes a first cavity for the carrier and a second cavity for the expandable material, allowing both components to be formed and bonded simultaneously in one operation, eliminating the need for separate tooling operations and reducing overall tooling cost.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mold is designed to perform multiple functions: it molds the carrier, molds the expandable material, and provides the bonding interface between them. This multi-functional tooling approach consolidates what would traditionally require separate specialized tools, reducing tooling complexity and cost while maintaining product performance.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If mechanical fasteners or adhesives are used to assemble separately produced foamable material and carrier, then the components can be joined, but device complexity and manufacturing steps increase

Engineering Contradiction:

Improveassembly processVSAvoidnumber of components and fasteners

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The carrier and expandable material are molded together as an integrated assembly within the same mold. The carrier includes a bonding surface that directly contacts and bonds with the expandable material during the molding process, eliminating the need for separate fasteners, adhesives, or assembly steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The bonding interface is prepared in advance during the molding process. The carrier is molded with a specific bonding surface configuration that facilitates direct bonding with the expandable material before any assembly operations are required, simplifying the final assembly process.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If multiple separate molding operations are used for carrier and expandable material, then each component can be optimized, but manufacturing time and productivity decrease

Engineering Contradiction:

Improvecomponent optimizationVSAvoidmanufacturing cycle time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The mold simultaneously forms both the carrier and the expandable material in a single molding cycle. The first cavity forms the carrier while the second cavity forms the expandable material, and both are bonded together during the same operation, significantly reducing manufacturing cycle time compared to sequential operations.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The molding process continues uninterrupted for both components. While the carrier is being molded in the first cavity, the expandable material is simultaneously molded in the second cavity, and both bonding operations occur in continuous parallel action rather than sequential steps.

Inventive Principle:

Principle #20Continuity of useful action

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 approach reduces tooling costs and improves the acoustic and sealing performance of baffles or reinforcements by enabling efficient formation and bonding of expandable and carrier materials, resulting in effective structural support and noise attenuation.

Implementation Method 1

When inserted into the cavity and by the action of the heat applied in the electrophoresis baking oven, the foam material expands to seal the cavity and/or bond the carrier to the member

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

overmolding a carrier material onto the expandable material in a second cavity of the mold partially defined by the first side and the second side

Methodology Applied

Scientific EffectChemical adhesion: Chemical Bonding

Data Source

PatentEP2507116B1Baffle or reinforcement reverse molding

Publication Date: 2023.04.19 SIKA TECH AG

Figure 1A~1B
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AI summary

A method of forming a baffle or reinforcement (170) comprises molding an expandable material (180) in a first cavity (130) of a mold (105) and molding a carrier material (175) onto the expandable material in a second cavity (135) of the mold (105).