Abstract: A physical barrier having a carrier device and a sealer material applied to the carrier device. The sealer material is configured to expand when it is activated. In its pre-activation state, the sealer material is flowable. The sealer material is applied directly to the carrier in its pre-activation state through a dispensing orifice without being previously molded.

Abstract: A physical barrier having a carrier device and a sealer material applied to the carrier device. The sealer material is configured to expand when it is activated. In its pre-activation state, the sealer material is flowable. The sealer material is applied directly to the carrier in its pre-activation state through a dispensing orifice without being previously molded.

Abstract: A baffle may conform to and be magnetically coupled to a body having a ferromagnetic component in proximity to the baffle. The baffle includes a first layer of a flexible thermally expansible baffle material which expands when subjected to an elevated temperature, and a second layer of a flexible magnetic material. The baffle may thereby be flexed to conform to an irregular or curved surface. In addition, the baffle may be preformed to provide an irregular or arcuate portion to conform to the body on which it is placed. The magnetic attachment facilitates attachment and removal without the need to provide holes in the body, and upon heating and expansion of the baffle, the baffle material expands to fill cavities and adhere to the inside wall surface of the body on which it is received.

Abstract: An expansible foaming reinforcing member for reinforcing a hollow structural member of an automobile, aircraft, boat, etc. is provided. The reinforcing member includes a synthetic, resin-based expansible reinforcing material secured to a carrier which maintains the reinforcing member at the desired location within the structural member until thermal expansion. The reinforcing material is formed of a thermally expansible composition which preferably has an expansion temperature similar to the temperatures achieved in specific stages of a particular manufacturing process (e.g., such as the temperature at which the paint bake or powder bake stage is carried out in the automobile manufacturing process). The reinforcing material of the inventive reinforcing member comprises a plurality of spaced-apart fins or ribs. During heat activation, heated air can travel between the ribs, thus allowing a greater surface area of the reinforcing material to be exposed to heat leading to improved expansion.

Abstract: An expandable baffle for sealing a cavity of an automobile is provided. The baffle includes a thermally expandable sealing material which has an expansion temperature similar to the temperatures achieved in specific stages of the automotive manufacturing processes (e.g., the paint bake stage). The inventive baffle further includes a support for the sealing material which maintains the material at the desired location within the cavity until thermal expansion. The support is formed of a material having a melting point higher than the thermal expansion temperature of the sealing material. In one embodiment, the support comprises a pair of solid, spaced-apart sidewalls that “bow” upon expansion of the sealing material. In an alternate embodiment, the sidewalls include a plurality of openings formed therein through which the sealing material flows during thermal expansion.