WO2020028316A1

WO2020028316A1 - Baffling member with rivet tab

Info

Publication number: WO2020028316A1
Application number: PCT/US2019/044062
Authority: WO
Inventors: Henry E. Richardson
Original assignee: Zephyros, Inc.
Priority date: 2018-08-02
Filing date: 2019-07-30
Publication date: 2020-02-06

Abstract

A baffle (10) comprising: (I) a carrier (12) having one or more lips (16) projecting substantially perpendicular to a surface of the carrier (12); (II) an adhesive material (14) disposed on the surface of the carrier (12) and abutting the one or more lips (16); and (III) a tab (30) projecting away from the carrier (12), the tab (30) being configured to abut one or more surfaces of one or more structural members (52A,52B).

Description

BAFFLING MEMBER WITH RIVET TAB

FIELD

[001] The present teachings generally relate to a baffling and reinforcing member, and more specifically, to a baffling and reinforcing member having one or more of an adhesive material and tab to secure the baffling and reinforcing member to one or more structural members.

BACKGROUND OF THE INVENTION

[002] Baffling members are used in a variety of industries, such as the transportation industry. Frequently, the baffling member may be positioned between one or more structural members to decrease or eliminate noise resulting from vibration of the one or more structural members. Additionally, the baffling member may be configured to provide additional structural support to the one or more structural members.

[003] Baffling members may include one or more adhesive materials disposed on a carrier. The carrier may act as a structural reinforcing member in combination with the adhesive materials. The adhesive materials may be any adhesive material that adheres the baffling member to the one or more structural members, provides additional structural integrity to the one or more structural members, or both. The adhesive materials may also be configured to be activated upon an increased temperature, an activation agent, or both.

[004] Frequently, baffling members need to be secured in a desired position on the one or more structural members prior to activation of the adhesive material so that the adhesive material may properly adhere to the one or more structural members upon activation. However, the baffling member may rotate or move relative to the one or more structural members during assembly, causing improper joining of the baffling member to the one or more structural members. Additionally, the baffling member may over time break away from the one or more structural members due to a breakdown of the adhesive material.

[005] Examples of baffling members are disclosed in U.S. Patent Nos. 8,801 ,079;

8,967,327; 9,010,843; and 9,776,368, all of which are incorporated by reference herein for all purposes. It would be attractive to have a baffling member that includes one or more structural features that prevent unwanted movement or rotation of the baffling member prior to activation of the adhesive material. What is needed is a baffling member having one or more mechanical attachment points. It would be attractive to have a baffling member that may be secured to one or more structural members free of contact of the adhesive material prior to activation of the adhesive material. What is needed is a baffling member having one or more surfaces free of adhesive material that contact the one or more structural members. It would be attractive to have one or more manufacturing aids that properly align the baffling member and the one or more structural members prior to assembly. What is needed is one or more alignment features on both the baffling member and the one or more structural members.

SUMMARY

[006] The present teachings meet one or more of the present needs by providing a baffle comprising: (I) a carrier having one or more lips projecting substantially perpendicular to a surface of the carrier; (II) an adhesive material disposed on the surface of the carrier and abutting the one or more lips; and (III) a tab projecting away from the carrier, the tab being configured to abut one or more surfaces of one or more structural members.

[007] The present teachings meet one or more of the present needs by providing a structural assembly comprising: (I) a first structural member; (II) a second structural member located adjacent to the first structural member; and (III) a baffle according to the teachings herein, wherein the baffle is secured to the first structural member, the second structural member, or both.

[008] The present teachings meet one or more of the present needs by providing a method of assembling a structural assembly, comprising the steps of: (I) abutting the first structural member and the second structural member to create a gap between at least a portion of the first structural member and the second structural member; (II) placing the baffle so that the opening located on the projection of the tab is substantially aligned with the opening on a surface of the first structural member and a peripheral edge of the carrier abuts the second structural member; (III) inserting a head of the rivet into the substantially aligned openings so the head extends through both the tab and the first structural member; (IV) moving a mandrel of the rivet in a direction substantially opposing the head of the rivet so that the mandrel deforms the head and creates a joint between the tab and the first structural member; and (V) activating the adhesive material.

[009] The present teachings meet one or more of the present needs by providing a baffling member, wherein: the tab abuts the one or more surfaces of the one or more structural members and a fastener secures the tab to the one or more structural members; the tab and the one or more structural members include an opening so that, when the openings of the tab and the one or more structural members are substantially aligned, a fastener extends through the openings to secure the baffle to the one or more structural members; the fastener is a rivet; the tab includes one or more gussets connecting a surface of the tab to the lip of the carrier; a surface of the tab that abuts the one or more surfaces of the one or more structural members is substantially parallel to a surface of the adhesive material free of contact with the carrier; the adhesive material is disposed on the surface of the carrier along a peripheral edge of the carrier and also abuts protrusion of the carrier; after the baffle is secured to the one or more structural members, the adhesive material is activated to adhere the baffle to the one or more structural members; the baffle abuts a first structural member along a peripheral edge of the carrier and the tab of the carrier abuts a surface of a second structural member; the adhesive material is heat- activated; the tab is coplanar with the carrier, the adhesive material, or both; wherein the carrier includes one or more recesses joined by one or more strengthening ribs on an opposing surface of the carrier relative to the adhesive material; the tab of the baffle is secured to the second structural member via a rivet and a peripheral edge of the baffle abuts a surface of the second structural member; the baffle is secured to the second structural member via the rivet and the adhesive material after the adhesive material is activated; the baffle is secured to the first structural member via the adhesive material after the adhesive material is activated; the adhesive material is non-tacky and dry to the touch prior to activation; the head of the rivet is deformed to have a diameter greater than a dimeter of the openings of the tab and the first structural member; the tab and the first structural member are sandwiched between the deformed head of the rivet and a body of the rivet, the body of the rivet having a diameter greater than the openings of the tab and the first structural member; or a combination thereof.

[0010] The present teachings provide: a baffling member that includes one or more structural features that prevent unwanted movement or rotation of the baffling member prior to activation of the adhesive material; a baffling member having one or more mechanical attachment points; a baffling member that may be secured to one or more structural members free of contact of the adhesive material prior to activation of the adhesive material; a baffling member having one or more surfaces free of adhesive material that contact the one or more structural members; a baffling member with one or more manufacturing aids that properly align the baffling member and the one or more structural members prior to assembly; and a baffling member with one or more alignment features on both the baffling member and the one or more structural members.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] FIG. 1 is a top perspective view of a baffle structure having a fastener;

[0012] FIG. 2 is a bottom perspective view of a baffle structure having a fastener;

[0013] FIG. 3 is a bottom perspective view of a baffle structure; [0014] FIG. 4 is a top perspective view of a structural assembly; and

[0015] FIG. 5 is a bottom perspective view of a structural assembly.

DETAILED DESCRIPTION

[0016] The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the teachings, its principles, and its practical application. Those skilled in the art may adapt and apply the teachings in its numerous forms, as may be best suited to the requirements of a particular use. Accordingly, the specific embodiments of the present teachings as set forth are not intended as being exhaustive or limiting of the teachings. The scope of the teachings should, therefore, be determined not with reference to the description herein, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. Other combinations are also possible as will be gleaned from the following claims, which are also hereby incorporated by reference into this written description.

[0017] This application claims the benefit of the filing date of United States Provisional

Application No. 62/713,768, filed August 2, 2018, the contents of that application being hereby incorporated by reference herein for all purposes.

[0018] The teachings herein relate to a baffling structure. The baffling structure may function to baffle noise caused by vibration and/or air flow between one or more structural members. The baffling structure may function to provide structural reinforcement to one or more structural members. The baffling structure may be configured for any industry requiring baffling and/or structural reinforcement, such as automotive, aeronautical, aerospace, residential and/or commercial real estate construction, transportation, exercise equipment, or the like. For example, the baffling structure may be positioned in a gap between one or more surfaces of one or more structural members so that the baffling structure substantially fills the gap between the one or more surfaces of the one or more structural members. The baffling structure may be positioned in the gap to provide additional structural reinforcement during compression, deflection, or both of the one or more structural members. The baffling structure may include a carrier, adhesive material, or both. The baffling structure may include one or more tabs to secure the baffling structure to one or more structural members. The baffling structure may include one or more surfaces, one or more components, one or more sub-assemblies, one or more fasteners, or a combination thereof. All or a portion of the baffling structure may be sufficiently rigid so that the baffling structure maintains its shape during assembly, during deflection and/or compression of one or more structural members abutting the baffling structure, during disassembly, or a combination thereof. For example, the baffling structure may include a structurally rigid carrier that maintains its shape after assembly while an adhesive material disposed on the carrier may deform during activation to adhere the baffling structure to one or more structural members. The baffling structure may be tuned to baffle noise due to vibration of one or more structural members by a desired percentage based on a configuration of the adhesive material, the carrier, or both. The baffling structure may baffle noise due to vibration of one or more structural members by about 50% or more, about 60% or more, or about 70% or more. The baffling structure may baffle noise due to vibration of one or more structural members by about 100% or less, about 90% or less, or about 80% or less. The baffling structure may be tuned to increase structural integrity (i.e., increase structural load capacity, decrease compressibility, decrease deflection, decrease torsion, decrease failure, or a combination thereof) of one or more structural members. The baffling structure may increase structural integrity of one or more structural members by about 50% or more, about 75% or more, or about 100% or more. The baffling structure may increase structural integrity of one or more structural members by about 200% or less, about 175% or less, about 150% or less, or about 125% or less. The baffling structure may baffle noise dues to vibration or air flow, increase structural integrity, or both based upon a configuration of a carrier of the baffling structure.

[0019] The carrier may function as a substrate for one or more adhesive materials of the baffling structure. The carrier may function to provide structural integrity to the baffling structure, one or more structural members, or both. The carrier may be structurally rigid or may be flexible to allow for compression of the carrier. The carrier may include one or more contours, one or more recesses, one or more projections, or a combination thereof. For example, the carrier may include one or more recesses on a surface spaced apart by strengthening ribs. The one or more recesses and strengthening ribs may vary in size and shape based upon a desired configuration of the carrier. The carrier may include one or more substantially flat surfaces to receive one or more adhesive materials disposed on the surface. For example, the carrier may include a first surface having at least a portion of the surface substantially flat to receive the one or more adhesive materials while an opposing second surface of the carrier includes one or more recesses and one or more strengthening ribs to increase structural integrity of the carrier. The carrier may include one or more projections, steps, bumps, or a combination thereof. For example, the adhesive material may be disposed on a surface of the carrier near a peripheral edge of the carrier and substantially surround a projection of the carrier. The carrier may be any desired size and shape.

[0020] The carrier may be formed from any material based upon a desired application.

The carrier may be formed from a polymer, plastic, metal, fibrous material, or a combination thereof. For example, the carrier may be injection-molded and formed of a polymer-based material. The carrier may include one or more structural reinforcements. For example, the carrier may include a desired amount of fibers (e.g., woven fibers, non-woven fibers, fiber mats or some combination thereof) to reinforce the carrier. The carrier may include one or more surface treatments to improve bonding to the one or more adhesive materials or may be free of any surface treatments. One or more surfaces of the carrier may be configured to increase friction between the carrier and the one or more adhesive materials. For example, one or more surfaces of the carrier may include one or more friction modifiers, such as an abrasive liner.

[0021] The carrier may include one or more lips. The lips may function to establish a peripheral edge of the carrier. The lips may be positioned so that the one or more adhesive materials abut the lip when disposed on the carrier. The lips may project from one or more surfaces of the carrier. The lips may project substantially orthogonal to one or more surfaces of the carrier or any angle other than substantially orthogonal. The lips may form an angle with a surface of the carrier of about 15° or more, about 30° or more, or about 45° or more. The lips may form an angle with a surface of the carrier of about 90° or less, about 75° or less, or about 60° or less. The lips may be positioned along a peripheral edge of the carrier or anywhere along the carrier. The lips may vary in thickness, size, or both. The lips may be integrally formed with the carrier or may be a separate component secured to the carrier. The lips may include one or more contours, one or more projections, one or more recesses, or a combination thereof. The lips may be structurally rigid or may be flexible.

[0022] A tab may project from a surface of the lip. The tab may function to abut a surface of one or more structural members so that the tab may secure the baffling structure to the one or more structural members. The tab may project away from a surface of the lips, the carrier, the one or more adhesive materials, or a combination thereof. The tab may be integrally formed with the carrier. The tab may be structurally rigid. The tab may be any size and shape desired to abut one or more structural members. A plurality of tabs may extend from a single baffling structure to abut one or more structural members. The tab may be coplanar with the one or more adhesive materials, a surface of the carrier, a surface of the lips, or a combination thereof. The tab may be substantially parallel to the one or more adhesive materials, a surface of the carrier, surface of the lips, or a combination thereof. The tabs may form any angle with the one or more adhesive materials, a surface of the carrier, surface of the lips, or a combination thereof so that the tab abuts one or more structural members and sits substantially flush with and may lie in direct planar contact with a surface of the one or more structural members.

[0023] The tab may include one or more projections that form a surface so that the tab may abut one or more surfaces of one or more structural members. The projection may be integrally formed with the carrier. For example, the tab may be integrally formed during injection molding of the carrier. The projection may be connected to the carrier. For example, the projection may be welded, fastened, adhered, or a combination thereof to the carrier. The projection may be integrally formed with the carrier. The projection may be substantially parallel to the one or more adhesive materials, a surface of the carrier, a surface of the lips, or a combination thereof. The projection may form any angle with the one or more adhesive materials, a surface of the carrier, a surface of the lips, or a combination thereof so that the projection abuts one or more structural members and sits substantially flush with a surface of the one or more structural members. A plurality of projections may form the tab. The projection may include one or more alignment structures to align the tab with one or more structural members. The projection may include one or more openings that align with one or more structural members. For example, the projection may include a hole (e.g., an opening) that aligns with a hole of a structural member so that a fastener may be inserted through both the hole of the projection and the hole of the structural member. The opening may be any size and shape. The opening may have a substantially uniform shape or may taper (e.g., the opening is conical). The projection may include one or more contours, one or more bends, or both. The projection may include one or more fingers, one or more keys, or both that may be received by one or more engaging features of one or more structural members. The projection may be secured to the carrier via one or more gussets.

[0024] The gussets may function to secure the tab to the carrier. The gussets may secure the projection of the tab to a lip of the carrier, a surface of the carrier, or both. The gussets may extend between a surface of the projection of the tab and a surface of the lip. The gussets may be integrally formed with the tab, the carrier, or both. The gussets may be any size and shape. The gussets may increase structural integrity of the tab. For example, the gussets may prevent unwanted bending or deformation of the tab during assembly, prior to assembly, after assembly, or a combination thereof. The gussets may maintain a position of the tab relative to the carrier so that an opening of the tab may align with an opening of one or more structural members to receive one or more fasteners. [0025] The fasteners may function to secure the baffling structure to one or more structural members. The fasteners may join the tab to one or more surfaces of one or more structural members. The fasteners may mechanically join the baffling structure and one or more structural members. The fasteners may be free of mechanically joining the baffling structure and one or more structural members. For example, the fasteners may chemically bond the baffling structure and the one or more structural members. The fasteners may be a screw, bolt, nail, weld, latch, pin, hook, clip, or a combination thereof.

[0026] The fastener may be a rivet. The rivet may function to extend through openings of the baffling structure and one or more structural members to secure the baffling structure to the one or more structural members. The rivet may function to deform and create a joint between the baffling structure and the one or more structural members. For example, a head of the rivet may be inserted and extend through openings of the baffling structure and the one or more structural members so that a mandrel connected to the head is moved in a direction substantially away from the head so that the head is deformed to join the baffling structure and the one or more structural members. The rivet may include a head, mandrel, body, or a combination thereof. The rivet may be a solid head rivet, semi-tubular rivet, blind rivet, oscar rivet, drive rivet, flush rivet, friction-lock rivet, self-piercing rivet, or a combination thereof. The rivet may be made from steel, brass, copper, stainless steel, aluminum, or a combination thereof. The rivet may be made from a polymeric material. The rivet may be plated to prevent corrosion or degradation. The rivet may be plated with zinc, nickel, brass, tin, or a combination thereof. The rivet may include a head.

[0027] The head of the rivet may function to deform after being inserted into the opening of the baffling structure, the one or more structural members, or both to join the baffling structure and the one or more structural members. The head may be connected to a body of the rivet, a mandrel or the rivet, or both. The head may deform to a size greater than a size of the opening of the baffling structure, the one or more structural members, or both. The baffling structure and the one or more structural members may be sandwiched between the deformed head and a body of the rivet. The head may be deformed by a mandrel connected to the head.

[0028] The mandrel may function to deform the head of the rivet. The mandrel may be a shaft extending away from and connected to the head of the rivet. The mandrel may break away from the rivet after deformation of the head. The mandrel may be configured to move in a direction substantially axially away from the head of the rivet. The mandrel may include one or more bumps, one or more contours, or both that secure the mandrel to the head of the rivet. The mandrel may break away from the rivet so that a portion of the mandrel that remains is recessed from a body of the rivet. [0029] The body of the rivet may function to abut a surface of the tab, the one or more structural members, or both. The body may function to form a joint between the baffling structure and the one or more structural members in conjunction with the head of the rivet. The body may include an opening, flange, or both. The body may remain connected to the head after the mandrel is disconnected from the rivet. The body may be structurally rigid and free of deformation. A portion of the body may house the mandrel so that, after assembly, the mandrel extends through the body and through the opening of the baffling structure, the one or more structural members, or both.

[0030] The rivet may maintain a position between the baffling structure and one or more structural members prior to activation of the one or more adhesive materials. The one or more adhesive materials may function to adhere the baffling structure to the one or more structural members. The one or more adhesive materials may function to baffle noise (e.g., from vibration and/or air flow) of the one or more structural members. The one or more adhesive materials may function to provide structural reinforcement to the one or more structural members. The adhesive materials may be any adhesive material that forms a bond between the baffling structure and the one or more structural members. The adhesive material may be activated by a stimulus such as heat, moisture, light, electricity, pressure, or some combination thereof. The adhesive may be chemically activated. The adhesive material may foam (e.g., expand) upon activation. The adhesive material may be dry to the touch, non-tacky, or both prior to activation. The adhesive material may be room stable.

[0031] The adhesive material may include an adhesive polymeric material. The adhesive may be based on epoxy, methacrylate, urethane, or some combination thereof. The adhesive material may include one or more of the following: an epoxy resin; a flexibilizer; a phenoxy resin; an impact modifier; a blowing agent; a curing agent; a filler; or a combination thereof. If the adhesive material is foamable, the adhesive material may expand to a volume greater than its volume in the unexpanded state (e.g., green state) (e.g., at least 5% greater, at least 20% greater or even possibly at least 50% greater). The volumetric expansion may be about 400% or less, about 300% or less, or about 200% or less relative to the original unexpanded volume. The volumetric expansion may be about 50% or more, about 100% or more, or about 150% or more relative to the original unexpanded volume. The adhesive material may cure upon activation (e.g., cross-link) for foamed and/or unfoamed versions of the adhesive material. A plurality of adhesive materials may be disposed on one or more surfaces of the carrier. One or more retaining features of the carrier may secure the adhesive materials to the carrier. The one or more retaining features may be a hook, latch, pin, column, flange, lip, or a combination thereof. Examples of adhesive materials may be found in U.S. Patent Nos. 6,846,559; 6,923,499; 7, 125,461 ; 7, 199, 165; 7,521 ,093; 7,892,396; 8,236, 128; 8,334,055; 8,475,694; and 8,702,889, all of which are incorporated by reference herein for all purposes. The adhesive materials may bond the baffling structure to the one or more structural members.

[0032] The structural members may function to provide support to one or more structures.

The structural members may be any member within a structure. For example, the structural members may be one or more panels, one or more pillars, or both of an automotive vehicle. The structural members may comprise metals, polymers, or both. For example, the structural members may be stamped steel, aluminum, iron, or a combination thereof. The structural members may include one or more contours, one or more bends, one or more ribs, one or more projections, one or more recesses, one or more openings, one or more bends, or a combination thereof. For example, the structural members may include an opening that substantially aligns with an opening of the tab of the baffling structure so that a fastener may extend through the openings and join the baffling structure to the structural members. The structural members may be structurally rigid. A plurality of structural members may be joined to one another. For example, a first and a second structural member may be joined to each other and have a baffling structure disposed within a gap between the first and the second structural members to baffle vibration, noise, or both. The baffling structure may be secured to the first structural member, the second structural member, or both via the one or more fasteners, the one or more adhesive materials, or both.

[0033] Turning now to the figures, FIG. 1 illustrates a top perspective view of a baffle structure 10. The baffle structure 10 includes a carrier 12 having an adhesive material 14 disposed on a bottom surface of the carrier 12. An opposing top surface of the carrier 12 includes a plurality of recesses 18 spaced apart by a strengthening rib 20. A tab 30 projects from and abuts a lip 16 of the carrier 12. The tab 30 includes a plurality of gussets 34 connecting a projection 32 of the tab 30 to the lip 16. A fastener 40, shown as a rivet 40A, is inserted into an opening (not shown) of the tab 30 so that the baffle structure 10 may be secured to one or more structural members (see FIGS. 4 and 5). During assembly, the tab 30 may abut a surface of the one or more structural members so that a body 46 of the rivet 40A extending through the opening of the tab 30 is inserted into a respective opening of the one or more structural members. Once inserted, a mandrel 42 extending through a head 44 of the rivet 40A is moved in a direction substantially away from the body 46 until the mandrel 42 fractures and disconnects from the rivet 40A, thereby deforming the body 46 and forming a joint between the baffle structure 10 and the one or more structural members. [0034] FIGS. 2 and 3 illustrate a bottom perspective view of a baffle structure 10. The baffle structure 10 includes a carrier 12 having an adhesive material 14 disposed on a bottom surface of the carrier 12. The adhesive material 14 is positioned along a peripheral edge of the carrier 12 and abuts a protrusion 22 of the carrier 12. A tab 30 projects from and abuts a lip 16 of the carrier 12. The tab 30 includes a plurality of gussets 34 connecting a projection 32 of the tab 30 to the lip 16. A fastener 40, shown as a rivet 40A, is inserted into an opening 36 of the tab 30 so that the baffle structure 10 may be secured to one or more structural members (see FIGS. 4 and 5). During assembly, the tab 30 may abut a surface of the one or more structural members so that a body 46 of the rivet 40A extending through the opening 36 of the tab 30 is inserted into a respective opening of the one or more structural members. Once inserted, a mandrel 42 extending through a head of the rivet 40A is moved in a direction substantially away from the body 46 until the mandrel 42 fractures and disconnects from the rivet 40A, thereby deforming the body 46 and forming a joint between the baffle structure 10 and the one or more structural members.

[0035] FIG. 4 illustrates a top perspective view of a structural assembly 50. The structural assembly 50 includes a baffle structure 10 and a plurality of structural members 52. A peripheral edge of the baffle structure 10 abuts a surface of a first structural member 52A. The baffle structure 10 includes a carrier 12 having an adhesive material disposed on a bottom surface of the carrier 12 (see FIGS. 2 and 3). An opposing top surface of the carrier 12 includes a plurality of recesses 18 spaced apart by a strengthening rib 20. A tab 30 projects from and abuts a lip 16 of the carrier 12. The tab 30 includes a plurality of gussets 34 connecting a projection 32 of the tab 30 to the lip 16 so that the tab 30 abuts a surface of a second structural member 52B. A fastener 40, shown as a rivet 40A, is inserted into substantially aligned openings (not shown) of the tab 30 and the second structural member 52B so that the baffle structure 10 may be secured to the second structural member 52B. A body of the rivet 40A is inserted and extends through the openings of the tab 30 and the second structural member 52B. Once inserted, a mandrel 42 extending through a head 44 of the rivet 40A is moved in a direction (D) substantially away from the body until the mandrel 42 fractures and disconnects from the rivet 40A, thereby deforming the body and forming a joint between the baffle structure 10 and the second structural member 52B (see FIG. 5).

[0036] FIG. 5 illustrates a bottom perspective view of a structural assembly 50. The structural assembly 50 includes a baffle structure 10 and a plurality of structural members 52. A peripheral edge of the baffle structure 10 abuts a surface of a first structural member 52A. The baffle structure 10 includes a carrier 12 having an adhesive material 14 disposed on a bottom surface of the carrier 12. The adhesive material 14 is positioned along a peripheral edge of the carrier 12 and abuts a protrusion 22 of the carrier 12. A tab 30 projects from and abuts a lip 16 of the carrier 12. The tab 30 includes a plurality of gussets 34 connecting a projection 32 of the tab 30 to the lip 16 so that the tab 30 abuts a surface of a second structural member 52B. A fastener 40, shown as a rivet 40A, is inserted into substantially aligned openings 36 of the tab 30 and the second structural member 52B so that the baffle structure 10 may be secured to the second structural member 52B. A body 46 of the rivet 40A is inserted and extends through the openings of the tab 30 and the second structural member 52B. Once inserted, a mandrel 42 extending through a head of the rivet 40A is moved in a direction (D) substantially away from the body 46 until the mandrel 42 fractures and disconnects from the rivet 40A, thereby deforming the body 46 and forming a joint between the baffle structure 10 and the second structural member 52 B (see FIG. 4).

[0037] The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the invention, its principles, and its practical application. The above description is intended to be illustrative and not restrictive. Those skilled in the art may adapt and apply the invention in its numerous forms, as may be best suited to the requirements of a particular use.

[0038] Accordingly, the specific embodiments of the present invention as set forth are not intended as being exhaustive or limiting of the teachings. The scope of the teachings should, therefore, be determined not with reference to this 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. The omission in the following claims of any aspect of subject matter that is disclosed herein is not a disclaimer of such subject matter, nor should it be regarded that the inventors did not consider such subject matter to be part of the disclosed inventive subject matter.

[0039] Plural elements or steps can be provided by a single integrated element or step.

Alternatively, a single element or step might be divided into separate plural elements or steps.

[0040] The disclosure of "a" or "one" to describe an element or step is not intended to foreclose additional elements or steps.

[0041] While the terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as“first,”“second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings.

[0042] Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,”

“above,”“upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as“below” or“beneath” other elements or features would then be oriented“above” the other elements or features. Thus, the example term“below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0043] The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. Other combinations are also possible as will be gleaned from the following claims, which are also hereby incorporated by reference into this written description.

[0044] Unless otherwise stated, a teaching with the term“about” or“approximately” in combination with a numerical amount encompasses a teaching of the recited amount, as well as approximations of that recited amount. By way of example, a teaching of “about 100” encompasses a teaching of within a range of 100 +/- 15.

Claims

CLAIMS What is claimed is:

1. A baffle comprising:

I. a carrier having one or more lips projecting substantially perpendicular to a surface of the carrier;

II. an adhesive material disposed on the surface of the carrier and abutting the one or more lips; and

III. a tab projecting away from the carrier, the tab being configured to abut one or more surfaces of one or more structural members.

2. The baffle according to claim 1 , wherein the tab abuts the one or more surfaces of the one or more structural members and a fastener secures the tab to the one or more structural members.

3. The baffle according to claims 1 or 2, wherein the tab and the one or more structural members include an opening so that, when the openings of the tab and the one or more structural members are substantially aligned, a fastener extends through the openings to secure the baffle to the one or more structural members.

4. The baffle according to any of the preceding claims, wherein the fastener is a rivet.

5. The baffle according to any of the preceding claims, wherein the tab includes one or more gussets connecting a surface of the tab to the lip of the carrier.

6. The baffle according to any of the preceding claims, wherein a surface of the tab that abuts the one or more surfaces of the one or more structural members is substantially parallel to a surface of the adhesive material free of contact with the carrier.

7. The baffle according to any of the preceding claims, wherein the adhesive material is disposed on the surface of the carrier along a peripheral edge of the carrier and also abuts protrusion of the carrier.

8. The baffle according to any of the preceding claims, wherein after the baffle is secured to the one or more structural members, the adhesive material is activated to adhere the baffle to the one or more structural members.

9. The baffle according to any of the preceding claims, wherein the baffle abuts a first structural member along a peripheral edge of the carrier and the tab of the carrier abuts a surface of a second structural member.

10. The baffle according to any of the preceding claims, wherein the adhesive material is heat- activated.

11. The baffle according to any of the preceding claims, wherein the tab is coplanar with the carrier, the adhesive material, or both.

12. The baffle according to any of the preceding claims, wherein the carrier includes one or more recesses joined by one or more strengthening ribs on an opposing surface of the carrier relative to the adhesive material.

13. The baffle according to any of the preceding claims, wherein the baffle is a structural reinforcing member of a vehicle.

14. A structural assembly comprising:

I. a first structural member;

II. a second structural member located adjacent to the first structural member; and

III. a baffle according to any of the preceding claims, wherein the baffle is secured to the first structural member, the second structural member, or both.

15. The structural assembly according to claim 13, wherein the tab of the baffle is secured to the second structural member via a rivet and a peripheral edge of the baffle abuts a surface of the second structural member.

16. The structural assembly according to claim 14, wherein the baffle is secured to the second structural member via the rivet and the adhesive material after the adhesive material is activated.

17. The structural assembly according to claim 15, wherein the baffle is secured to the first structural member via the adhesive material after the adhesive material is activated.

18. The structural assembly according to any of claims 14 through 17, wherein the adhesive material is non-tacky and dry to the touch prior to activation.

19. A method of assembling the structural assembly according to any of claims 14 through 18, comprising the steps of:

I. abutting the first structural member and the second structural member to create a gap between at least a portion of the first structural member and the second structural member;

II. placing the baffle so that the opening located on the projection of the tab is substantially aligned with the opening on a surface of the first structural member and a peripheral edge of the carrier abuts the second structural member;

III. inserting a head of the rivet into the substantially aligned openings so the head extends through both the tab and the first structural member;

IV. moving a mandrel of the rivet in a direction substantially opposing the head of the rivet so that the mandrel deforms the head and creates a joint between the tab and the first structural member; and

V. activating the adhesive material.

20. The method according to claim 19, wherein the head of the rivet is deformed to have a diameter greater than a dimeter of the openings of the tab and the first structural member.

21. The method according to claim 20, wherein the tab and the first structural member are sandwiched between the deformed head of the rivet and a body of the rivet, the body of the rivet having a diameter greater than the openings of the tab and the first structural member.

22. The method according to any of claims 19 through 21 , wherein the first structural member and the second structural member are structural members of a vehicle.