System and method for manufacturing physical barriers

Abstract

A physical barrier having a carrier device and a sealer material applied to the carrier device. The sealer material is configured to expand when it is activated. In its pre-activation state, the sealer material is flowable. The sealer material is applied directly to the carrier in its pre-activation state through a dispensing orifice without being previously molded.

What is claimed is:  
     
         1 . A barrier-manufacturing system comprising: 
 a flowable, pre-activation, expandable sealer material; and    a dispensing orifice configured to dispense said sealer material onto a carrier, said carrier being configured to be installed on an object having an opening.    
     
     
         2 . The system of  claim 1 , wherein said dispensing orifice is positioned on a robot arm.  
     
     
         3 . The system of  claim 1 , further comprising a movement device configured to position said carrier relative to said dispensing orifice prior to said dispensing orifice dispensing said sealer material.  
     
     
         4 . The system of  claim 3 , wherein said movement device is selected from a group consisting of a conveyor belt, a reciprocating table, and a turntable.  
     
     
         5 . The system of  claim 1 , wherein said sealer material is heat-activated.  
     
     
         6 . The system of  claim 1 , wherein said sealer material is chemically-activated.  
     
     
         7 . The system of  claim 1 , wherein said dispensing orifice is configured to apply an amount of said sealer material to said carrier corresponding to a desired sound transmission level through the barrier.  
     
     
         8 . A method of manufacturing a physical barrier, comprising the steps: 
 changing a relative physical positioning between a dispensing orifice and a carrier, said carrier being adapted to be installed on an object having an opening; and    applying a flowable, pre-activation, expandable sealer material to said carrier from a dispensing orifice.    
     
     
         9 . The method of  claim 8 , further comprising the steps: 
 determining a desired sound transmission characteristic of the physical barrier; and    applying an amount of said flowable, pre-activation, expandable sealer material corresponding to said determined desired sound transmission characteristic.    
     
     
         10 . The method of  claim 8 , wherein said changing step comprises holding said carrier stationary and moving said dispensing orifice.  
     
     
         11 . The method of  claim 8 , wherein said changing step comprises holding said dispensing orifice stationary and moving said carrier.  
     
     
         12 . The method of  claim 8 , wherein said changing step comprises moving said dispensing orifice and said carrier simultaneously.  
     
     
         13 . A physical barrier, comprising 
 a carrier device configured to be installed on an object having an opening; and    a pre-activation, non-molded, expandable sealer material applied to said carrier.    
     
     
         14 . The physical barrier of  claim 13 , wherein an amount of said sealer applied to the carrier corresponds to a desired sound transmission characteristic of the barrier.  
     
     
         15 . The physical barrier of  claim 13 , wherein said sealer is applied to a placement area on said carrier, said placement area being chosen from a group of a ledge, a trough, and a well.  
     
     
         16 . The physical barrier of  claim 15 , wherein said sealer material is heat-activated.  
     
     
         17 . The physical barrier of  claim 15 , wherein said sealer material is chemically-activated.