Patent ID: 8801079

Claim:
A method for baffling, reinforcing or sealing of a cavity of a vehicle comprising: providing a pre-formed insert, the insert including: i. a first pre-installation configuration including a carrier structure and an expandable material supported on the carrier structure; ii. a plurality of living hinges, each hinge configured for enabling local elastic deformation of the insert in a respective pre-determined direction; iii. an attachment portion; iv. at least one contact surface located external of the expandable material for defining a generally low-friction surface as compared with the expandable material and formed for spacing the expandable material from an opposing surface during subsequent installation steps; attaching the pre-formed insert to a first substrate; attaching a second substrate to the first substrate in overlying relationship with the first substrate for defining a cavity with the insert there between while elastically deforming each of the living hinges of the insert in their respective pre-determined directions so that the insert assumes a second installed configuration different from the first pre-installation configuration; activating the expandable material while the insert is in the second installed configuration for causing it to foam and fill the cavity.