Baffle precursors
Baffle precursors are provided which comprise a sandwich of cellular plates with a foamable material therebetween these precursors overcome the problem of the flow of the foamable material as it is heated up to cause foaming which can result in non-homogeneous foam. The baffle precursors also enable uniform baffle properties to be established on both sides of the baffle and provide improved performance for a reduction in the amount of foamable material required. The hinged cellular plate is also an aspect of the invention.
1 - 13 . (canceled)
14 . A baffle precursor comprising:
a pair of support plates including a first support plate and a second support, the first support plate having a cellular structure and having an outer surface;
a foamable material located between first support plate and the second second support plate;
wherein, upon foaming, the foamable material expands and passes through the cellular structure of the first plate and expands to form a foam that substantially covers the entire outer surface of the first support plate.
15 . A baffle precursor as in claim 14 wherein the foamable material expands upon encountering an elevated temperature.
16 . A baffle precursor as in claim 15 wherein the first plate and the second plate are formed of materials which will withstand the elevated temperature.
17 . A baffle precursor as in claim 16 wherein the elevated temperature is between 130° C. and 200° C.
18 . A baffle precursor as in claim 16 wherein the elevated temperature is a temperature typically experienced in an automotive paint or e-coat oven.
19 . A baffle precursor as in claim 16 wherein the first and second plates are formed of a material selected from a metal or a high melting thermoplastic.
20 . A baffle precursor as in claim 19 wherein the material is a polyamide reinforced with fibres selected from glass fibres, carbon fibres and metal fibres.
21 . A baffle precursor as in claim 14 wherein the first plate and the second plate each have a thickness from 0.5 mm to 2.5 mm.
22 . A baffle precursor as in claim 14 wherein the first plate and the second plate each have a thickness from 1.0 mm to 1.5 mm.
23 . A baffle precursor as in claim 14 wherein the foamable material is selected from a thermoplastic material or a rubbery polymer and wherein the thermoplastic material is selected from a compolymer of ethylene and a vinyl ester or acrylic ester and wherein the vinyl ester or acrylic ester is selected from vinyl acetate, vinyl propionate, methyl acrylate, ethyl acrylate and butyl acrylate and wherein the rubbery polymer is selected from an ethylene propylene copolymer rubber and an ethylene, propylene dieneter polymer rubber.
24 . A baffle precursor as in claim 14 wherein the precursor includes an attachment for locating the prescursor within a hollow structure.
25 . A baffle precursor as in claim 14 wherein the foamable material is contained between the pair of support plates.
26 . A baffle precursor as in claim 14 wherein the first plate is hinged to the second plate and each of the first and second plates includes a portion of an attachment and the portion of the first plate engages the portion of the second plate and attach to each other to hold the plates together in a superimposed relationship.
27 . A baffle precursor comprising:
a pair of support plates including a first support plate and a second support plate, the first support plate and the second support plate having a cellular structure and having an outer surface, wherein the first plate is superimposed upon the second plate;
a foamable material located and contained between first support plate and the second second support plate;
wherein, upon foaming, the foamable material expands and passes through the cellular structure of the first plate and the second plate and expands to form a foam that substantially covers the entire outer surface of the first support plate and the second plate.
28 . A baffle precursor as in claim 27 wherein the first plate and the second plate are formed of materials which will withstand an elevated temperature between 130° C. and 200° C.
29 . A baffle precursor as in claim 27 wherein the first and second plates are formed of a polyamide reinforced with fibres selected from glass fibres, carbon fibres and metal fibres.
30 . A baffle precursor as in claim 27 wherein the first plate and the second plate each have a thickness from 1.0 mm to 1.5 mm.
31 . A baffle precursor as in claim 27 wherein the foamable material is selected from a thermoplastic material or a rubbery polymer and wherein the thermoplastic material is selected from a compolymer of ethylene and a vinyl ester or acrylic ester and wherein the vinyl ester or acrylic ester is selected from vinyl acetate, vinyl propionate, methyl acrylate, ethyl acrylate and butyl acrylate and wherein the rubbery polymer is selected from an ethylene propylene copolymer rubber and an ethylene, propylene dieneter polymer rubber.
32 . A baffle precursor as in claim 27 wherein the precursor includes an attachment for locating the prescursor within a hollow structure.
33 . A baffle precursor as in claim 27 wherein the first plate is hinged to the second plate and each of the first and second plates includes a portion of an attachment and the portion of the first plate engages the portion of the second plate and attach to each other to hold the plates together in a superimposed relationship.
34 . A baffle precursor comprising:
a pair of support plates including a first support plate and a second support plate, the first support plate and the second support plate having a cellular structure and having an outer surface, wherein the first plate is superimposed upon the second plate;
a foamable material located between first support plate and the second second support plate;
wherein, upon foaming, the foamable material expands and passes through the cellular structure of the first plate and the second plate and expands to form a foam that substantially covers the entire outer surface of the first support plate and the second plate; and
wherein the foamable material expands upon encountering an elevated temperature;
wherein the first plate and the second plate are formed of materials which will withstand the elevated temperature;
wherein the elevated temperature is a temperature typically experienced in an automotive paint or e-coat oven;
wherein the first and second plates are formed of a material selected from a polyamide reinforced with fibres selected from glass fibres, carbon fibres and metal fibres;
wherein the first plate and the second plate each have a thickness from 1.0 mm to 1.5 mm; and
wherein the foamable material is selected from a thermoplastic material or a rubbery polymer and wherein the thermoplastic material is selected from a compolymer of ethylene and a vinyl ester or acrylic ester and wherein the vinyl ester or acrylic ester is selected from vinyl acetate, vinyl propionate, methyl acrylate, ethyl acrylate and butyl acrylate and wherein the rubbery polymer is selected from an ethylene propylene copolymer rubber and an ethylene, propylene dieneter polymer rubber;
wherein the precursor includes an attachment for locating the prescursor within a hollow structure;
wherein the foamable material is contained between the pair of support plates; and
wherein the first plate is hinged to the second plate and each of the first and second plates includes a portion of an attachment and the portion of the first plate engages the portion of the second plate and attach to each other to hold the plates together in a superimposed relationship.