Fastenable member for sealing, baffling or reinforcing and method of forming same

Abstract

There is disclosed a member for sealing, baffling and/or reinforcing components of an automotive vehicle. The assembly generally includes a carrier, an expandable material and at least one fastener.

1 . A method of forming members for providing sealing, baffling or reinforcement to one or more structures, the method comprising:
 providing a carrier material, the carrier material including a base portion and two extensions extending upward from a substantially perpendicular to the base portion, the two extensions formed as walls;   disposing an expandable material upon the carrier material in a continuous manner, the expandable material being disposed in between the two extensions so that the expandable material does not extend beyond any edge of the two extensions;   
       and
 providing a fastener integrally molded with the carrier and extending from the base portion of the carrier material. 
 
     
     
         2 - 9  (canceled) 
     
     
         10 . The method as in  claim 1 , wherein the expandable material is a material that is thermally deformable at the temperature of extrusion, but upon thermal activation at an elevated temperature will cross link to form a thermoset material. 
     
     
         11 . The method as in claim  2 , wherein the expandable material includes a plastic selected from the group consisting of thermoplastics, thermosets, or a combination thereof or a resin selected from the group consisting of an epoxy resin, a thermoplastic resin, an acetate resin, an EPDM resin, a phenoxy resin, a polyurethane resin or a combination thereof. 
     
     
         12 . The method as in claim  2 , wherein the carrier material is formed at least partially of a material selected from a metal, a polymeric material, a carbon fiber, graphite, glass, or combinations thereof. 
     
     
         13 . The method as in  claim 12 , wherein the carrier material is a polymeric material that is selected from a polyolefin, a polyamide, a polyester, polystyrene, a poly(meth)acrylate, a polyvinyl chloride, a polysulfone, or combinations thereof. 
     
     
         14 . The method as in  claim 12 , wherein the carrier material is a polymeric material selected from polyethylene terephthalate, high density polyethylene, polyvinyl chloride, low density polyethylene, polypropylene, polystyrene, or combinations thereof. 
     
     
         15 . The method as in  claim 1 , wherein the carrier material is a polymeric material that is selected from a polycrystalline material, an amorphous material or a combination thereof. 
     
     
         16 . (canceled) 
     
     
         17 . The method as in claim  3 , wherein the carrier material includes a portion that has a shape selected from an alphanumeric shape, a polygonal shape, an arrowhead shape, a barb shape, is flat, is curved, or a combination thereof. 
     
     
         18 . The method as in  claim 1 , wherein the length of the member along its longitudinal axis is smaller than the height of the member. 
     
     
         19 . The method as in  claim 1 , wherein, prior to expansion of the expandable material, at least about 10% of the outer surface area of the carrier of each of the members is covered with the expandable material. 
     
     
         20 - 23  (canceled) 
     
     
         24 . The method as in claim  3 , wherein the expandable material volumetrically expands to a size that is at least 3000% its original size up exposure to elevated temperatures. 
     
     
         25 . The method as in  claim 1 , wherein the expandable material has a configuration that is selected from 1) substantially uniform thickness, 2) non-uniform thickness, 3) planar, 4) contoured, 5) geometric, 6) non-geometric, 7) circular cross-section, 8) triangular cross-section 9) rectangular cross-section. 
     
     
         26 . The method as in  claim 1 , wherein the expandable material includes a property or ingredient selected from a flame retardant, water remediation ingredient, an electrically conductive ingredient, a sound absorption characteristic. 
     
     
         27 - 38 . (canceled) 
     
     
         39 . The method as in  claim 1 , wherein the fastener is formed to engage an opening in a panel in an interference fit. 
     
     
         40 . The method as in  claim 39 , wherein the expandable material has a rectangular profile. 
     
     
         41 . The method as in  claim 40 , wherein the carrier material includes exactly two extensions extending perpendicular to and upward from the base portion. 
     
     
         42 . The method as in  claim 39 , wherein the expandable material is in a sandwich arrangement in between the two extensions. 
     
     
         43 . The method as in  claim 42 , wherein the base portion is formed of two extensions arranged substantially parallel to one another. 
     
     
         44 . The method of  claim 1 , wherein the base portion is formed of two extensions arranged substantially parallel to one another and substantially perpendicular to the two extensions formed as walls. 
     
     
         44 . The method of  claim 40 , wherein the base portion is formed of two extensions arranged substantially parallel to one another and substantially perpendicular to the two extensions formed as walls.