Expansion foam cavity filler and method

Abstract

A plastic or elastomeric foam cavity filler, useable for filling of cavities such as are found in vehicles, ships, boats, mobile or modular homes, buildings, machinery, and equipment comprises a flexible pouch containing at least one material suitable for chemical or thermal activation which, upon activation of the material, the flexible pouch is placed in a cavity. The material expands the pouch to fit the cavity in which it was placed, restricting the entrance of, or transmission through, of noise, vibration, or fumes. When more than one foam component material is used, the component materials are separated within the flexible pouch. Among the means of separation are a pouch within the flexible pouch or barriers forming separate compartments in the pouch.

1 . A device for filling cavities to reduce vibrations, noise and fumes from entering or being transmitted through said cavities, said device being a cavity filler comprising: 
 a) a flexible pouch containing at least one material wherein said material can be activated chemically or thermally so the material expands and cures to a shape conforming to the flexible pouch as contained in said cavity, becoming a cured foam cavity filler.    
   
   
       2 . The flexible pouch of  claim 1  wherein the flexible pouch is separated into compartments each containing a foam component that can be mixed to produce a cured foam cavity filler.  
   
   
       3 . The flexible pouch of  claim 1  wherein the flexible pouch comprises: 
 a) a first foam component,    b) a second foam component,    c) a means of separation of the first foam component from the second foam component wherein the means of separation can be eliminated, allowing the first foam component material to be combined with the second foam component material to result in a cured foam cavity filler.    
   
   
       4 . The flexible pouch of  claim 3  wherein the means of separation of the first foam component from the second foam component is a pouch within the flexible pouch, said pouch within the flexible pouch containing one of the foam components.  
   
   
       5 . The flexible pouch of  claim 4  wherein the pouch within the flexible pouch is of a thinner material than the flexible pouch.  
   
   
       6 . The flexible pouch of  claim 4  wherein the pouch within the flexible pouch is held in position within the flexible pouch by means of a seal between the pouch within the flexible pouch and the flexible pouch.  
   
   
       7 . The flexible pouch of  claim 3  wherein the means of separation of the first foam component material from the second foam component material is a barrier.  
   
   
       8 . The flexible pouch of  claim 7  wherein the barrier comprises: 
 a) a rod and    b) a clip that secures the flexible pouch between the rod and the clip so material contained within the flexible pouch cannot flow past the barrier.    
   
   
       9 . The cavity filler of  claim 1  for filling cavities wherein the device is used for filling cavities in vehicles, ships, boats, mobile or modular homes, buildings, machinery, and equipment.  
   
   
       10 . The cavity filler of  claim 1  further comprising a means of adhering the flexible pouch to a cavity wall in which the flexible pouch will be placed.  
   
   
       11 . The cavity filler of  claim 10  wherein the means of adhering the flexible pouch to the cavity wall comprises a pressure sensitive adhesive added as a coating to the flexible pouch.  
   
   
       12 . The cavity filler of  claim 10  wherein the means of adhering the flexible pouch to the cavity wall comprises a heat activated material added as a coating to the flexible pouch.  
   
   
       13 . The cavity filler of  claim 11  wherein the heat activated material is a hot melt glue.  
   
   
       14 . The cavity filler of  claim 10  wherein the means of adhering the flexible pouch to the cavity wall is using a flexible pouch composed of a heat-activateable material.  
   
   
       13 . The cavity filler of  claim 10  wherein the means of adhering the flexible pouch to the cavity wall is at least one push pin through an aperture in the flexible pouch and a clearance in the cavity wall.  
   
   
       15 . A method of filling cavities in vehicles, ships, boats, mobile or modular homes, buildings, machinery and equipment where an operator: 
 a) takes the flexible pouch of  claim 1 ,    b) activates material contained within the flexible pouch either chemically or thermally as dictated by the nature of the material contained within the flexible pouch, and    c) places the flexible pouch in a cavity to be filled.    
   
   
       16 . A method of filling cavities where an operator: 
 a) takes the flexible pouch of  claim 2 ,    b) allows the foam components to mix, and    c) places the flexible pouch in a cavity to be filled.