Flexible Cavity Sealing Member for Varying Tolerances
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Solution Overview
Problem
Existing sealing, baffling, and reinforcement devices face challenges in automotive and other industries due to difficulties in installation within varying tolerances and the need for rapid activation of activatable materials in diverse cavity configurations.
Innovation Solution
A modular member comprising a carrier with activatable material and extensions, featuring hinges and fasteners, designed to adapt to different cavity shapes and tolerances, allowing for flexible installation and rapid activation of the activatable material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional sealing and reinforcement devices are used, then installation within varying tolerances is difficult, but the structure requires proper sealing and reinforcement
Solution Approach 1:
The member incorporates a flexible carrier that can dynamically adapt its shape to fit varying cavity configurations and tolerances. The carrier's flexibility allows it to bend and conform to different geometries during installation, eliminating the need for precise pre-matching of rigid components to specific cavity dimensions.
Solution Approach 2:
The carrier is designed as a flexible structure that can deform to accommodate different cavity shapes and size variations. This flexible carrier supports the activatable material and provides the necessary adaptability to install the device in cavities with varying tolerances without requiring custom-fit rigid components.
2Productivity
If traditional activatable material application is used, then activation time is prolonged, but the structure requires effective sealing or reinforcement
Solution Approach 1:
The activatable material is pre-applied and pre-positioned on the flexible carrier before insertion into the cavity. This preliminary preparation ensures that once the carrier is installed, the activatable material is already in optimal position and requires minimal activation time, while still maintaining effective sealing or reinforcement functionality.
Solution Approach 2:
The member is designed as an integrated multi-functional unit where the flexible carrier simultaneously provides structural support, positioning, and support for the activatable material. This universal design allows rapid deployment while ensuring reliable sealing or reinforcement through the coordinated action of all components.
3Adaptability or versatility
If simple member designs are used, then installation flexibility in diverse cavity configurations is limited, but the structure requires adaptation to various cavity shapes
Solution Approach 1:
The flexible carrier provides dynamic adaptability to various cavity configurations through its ability to bend and conform to different shapes. This single flexible component replaces what would otherwise require multiple rigid components of varying geometries, achieving high adaptability without proportionally increasing overall device complexity.
Data Source
Figure 1~2C
Figure 3~5
Figure 6A~6B
AI summary
An article comprising: a carrier (12), activatable material (14) disposed on the carrier, one or more carrier extensions (16) extending from the carrier; wherein the article is adapted to provide sealing, baffling, or reinforcement within a structure's cavity.