Patent ID: 7484946

Claim:
A system for forming a baffle, the system comprising: a structure of an automotive vehicle, the structure defining a cavity and having an opening for providing access to the cavity, wherein the structure is a pillar, header, frame rail, or vehicle seat cross-bar; a first housing; and a second housing defining an internal open space and substantially surrounding the first housing, wherein the first housing includes at least one wall dividing the open space into a first compartment and a second compartment wherein the at least one wall is non-cylindrical and includes weakened sections that fracture upon application of the force; a curing agent, a blowing agent or both located in the first compartment or the second compartment, the curing agent, the blowing agent or both including water, an isocyanate or both; a polymeric material located in the first compartment or the second compartment separate from the curing agent, the blowing agent or both; a movable member connected to the first housing, the movable member including a head and a mixer; wherein the movable member, upon rotation thereof, rotates the mixer, which applies a force upon the at least one wall thereby fracturing the wall and intermixing the polymeric material, the curing agent and the blowing agent to form an admixture that expands, foams, and cures to form a foam that functions as a baffle for the cavity, wherein the second housing fails by melting, dissolving or rupturing upon foaming of the admixture such that the intermixing takes place within the structure of the automotive vehicle so that the baffle cannot be removed from the structure of the automotive vehicle.