Patent ID: 7428774

Claim:
A method of providing baffling to a cavity of an automotive vehicle, comprising: providing an elongated baffle having a carrier member formed of a molded plastic material and an expandable material at least partially disposed upon the carrier member for lateral expansion about the periphery of the carrier member, wherein the baffle extends the length of a fender panel and includes an outer edge that substantially conforms to the contour of the fender panel, and at least one opening extends through the baffle proximate to an inner edge of the baffle; installing the baffle in a cavity of a structure of an automotive vehicle between the fender panel and a hinge or A pillar of the vehicle; bending the baffle at a plurality of bend locations at a central area of the baffle during the installing step; passing a bolt at least partially, substantially entirely or entirely through the at least one opening of the baffle, and proximate to at least one of the plurality of bend locations in the central area and the inner edge; and expanding the expandable material to seal about the baffle and to seal the at least one opening of the baffle wherein the expandable material expands to: i. seal about the bolt; ii. contact and adhere to the bolt; wherein: i. the expandable material substantially seals about a periphery of the baffle; ii. the expandable material is substantially tack-free to the touch; and iii. the expandable material expands upon exposure to an elevated temperature in an e-coat or paint oven.