Baffle apparatus for a hollow structural member

Abstract

A baffle apparatus mountable in a hollow structural member includes first and second sealed containers, each containing a separate reactive component. The first and second containers are formed of complementary melting point materials so as to melt and allow the reactive components to mix and react when the thermal energy is applied to the structural member. The reactive components form an expanded volume foam mass substantially filling, sealing, and/or reinforcing the cross section of the structural member.

1 . A baffle apparatus for a hollow member, the baffle apparatus comprising: 
 a first container formed of a first melting point material mounted on the carrier;    a first reactive component in the first container;    a second container formed of a material having a melting point approximate the first melting point;    a second reactive component in the second container; and    the first and second containers disposed in proximity with each other wherein thermal energy applied to the first and second containers to raise the temperature of the first and second containers above the melting point of the materials forming the first and second containers releases the first and second components for reaction and expansion into the hollow structural member.    
   
   
       2 . The baffle apparatus of  claim 1  further comprising: 
 means for joining the first and second containers together.    
   
   
       3 . The baffle apparatus of  claim 2  wherein the joining means comprises: 
 complementary snap members formed on the first and second containers.    
   
   
       4 . The baffle apparatus of  claim 2  wherein the joining means comprises: 
 adhesive.    
   
   
       5 . The baffle apparatus of  claim 1  wherein: 
 at least one of the first and second containers is a blow molded container.    
   
   
       6 . The baffle apparatus of  claim 1  wherein: 
 the first and second containers are formed of materials having similar melt temperatures.    
   
   
       7 . The baffle apparatus of  claim 1  wherein the material forming the first and second containers is selected from the group consisting of polypropylene, thermoplastic olefin and polyethylene.  
   
   
       8 . The baffle apparatus of  claim 1  wherein the first and second reactive components react to form a foam.  
   
   
       9 . The baffle apparatus of  claim 1  wherein the first and second reactive components react to form a polyurethane foam.  
   
   
       10 . The baffle apparatus of  claim 1  wherein: 
 the first and second containers are sealed after the respective first and second reactive components are disposed therein.    
   
   
       11 . The baffle apparatus of  claim 1  further comprising: 
 means for fixing one of the first and second containers to the carrier.    
   
   
       12 . The baffle apparatus of  claim 1  further comprising: 
 a carrier mountable within a hollow member; and    at least one of the first and second container disposed on the carrier.    
   
   
       13 . The baffle apparatus of  claim 12  wherein: 
 the at least one of the first and second containers is fixed on the carrier.    
   
   
       14 . The baffle apparatus of  claim 12  wherein: 
 at least one of the first and second containers, the carrier, and means for joining the first and second container has a catalystic effect on the reaction of the first and second reactive components during the application of thermal energy to the components and the components are mixed.    
   
   
       15 . The baffle apparatus of  claim 1  further comprising: 
 means for enhancing mixing of the first and second reactive components after discharge of the first and second reactive components from the first and second containers.    
   
   
       16 . The baffle apparatus of  claim 15  wherein the mixing enhancing means comprises: 
 irregular surface means disposed in the path of flow of the first and second components after the first and second components have been discharged from the first and second containers.    
   
   
       17 . The baffle apparatus of  claim 16  wherein the irregular surface means comprises: 
 a plurality of steps of varying size.    
   
   
       18 . The baffle apparatus of  claim 17  further comprising: 
 a carrier mountable within a hollow member; and    the steps carried on the carrier.    
   
   
       19 . The baffle apparatus of  claim 18  wherein: 
 the steps extend from the carrier.    
   
   
       20 . The baffle apparatus of  claim 18  wherein: 
 the steps have increasing outer dimensions from a top to a bottom of the carrier.    
   
   
       21 . The baffle apparatus of  claim 16  wherein: 
 at least one of the first and second containers has a central area substantially devoid of one of the first and second reactive components, respectively.    
   
   
       22 . The baffle apparatus of  claim 21  further comprising: 
 a carrier mountable within a hollow member; and    the central area of at least one of the first and second containers contacting the carrier.    
   
   
       23 . The baffle apparatus of  claim 22  wherein: 
 the central area of at least one of the containers includes an aperture mountable about the carrier.    
   
   
       24 . The baffle apparatus of  claim 23  wherein: 
 at least a portion of the carrier extends through the aperture to assist in supporting the at least one of the first and second containers on the carrier.    
   
   
       25 . The baffle apparatus of  claim 16  further comprising: 
 a carrier mountable within a hollow member;    the irregular surface means including a plurality of steps having an exposed outer surface disposed in the flow path of the first and second reactive components after the first and second reactive components have been discharged from the first and second containers, the plurality of steps having increased outer dimensions from a top to a bottom of the carrier.