Method of forming members for sealing or baffling

1. A method of forming members for providing sealing or baffling to one or more structures, the method comprising:

providing a carrier material;

disposing an expandable material upon the carrier material in a continuous manner;

forming sealing or baffling members such that each of the members includes a carrier with the expandable material disposed thereon, the carrier being formed of the carrier material; and

providing a fastener connected to the carrier;

wherein the expandable material volumetrically expands to a size that is at least 2000% its original size upon exposure to elevated temperatures; and

wherein:

i. the step of forming the members includes dividing the carrier material, the expandable material or both to form the sealing or baffling members;

ii. the one or more structures are part of an automotive vehicle; and

iii. upon expansion of the expandable material, the expandable material forms a foam that substantially entirely spans the entirety of one or more cross-sections of a cavity of the one or more structures to prevent the passage of debris, water, sound, air or a combination thereof through the cavity.

2. A method as in claim 1 wherein the step of forming the members includes cutting the carrier material and the expandable material to form the sealing or baffling members.

3. A method as in claim 1 wherein the carrier material is provided as a strip or film of material and the expandable material is disposed upon the carrier material by extrusion.

4. A method as in claim 1 wherein the expandable material is disposed upon the carrier material by cross-head extrusion.

5. A method as in claim 1 wherein the fastener is a mechanical fastener that is separately attached to the carrier material.

6. A method as in claim 1 wherein the fastener is integrally formed of single material with the carrier material.

7. A method as in claim 1 wherein the carrier material is provided by extrusion and the carrier material is extruded simultaneously with the expandable material, the carrier material is extruded prior to the extrusion of the expandable material upon the carrier material or the carrier material is extrusion with the expandable material and the resulting coextrusion is further extruded to form a desired profile configuration.

8. A method as in claim 1 wherein the expandable material is adapted for forming a sealing material, an acoustical material, an adhesive, or a combination of at least two of the foregoing.

9. A method as in claim 1 wherein the carrier further includes a layer of a material over at least a portion of its surface that is applied thereto by coextrusion, lamination, adhesion, vapor deposition, plasma deposition, spray coating, brushing, swabbing, dipping, plating or combinations thereof.

10. A 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. A method as in claim 1 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. A method as in claim 1 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. A method as in claim 1 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. A method as in claim 1 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. A 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. A method as in claim 1 wherein the carrier material is a polymeric material that is paintable to result in a class A automotive vehicle surface finish.

17. A method as in claim 1 wherein the carrier material of each member 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. A method as in claim 1 wherein the length of each sealing or baffling member along its longitudinal axis is smaller than the height of each seadling or baffing member.

19. A 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. A method as in claim 1 wherein at least one end portion of the carrier of each of the members is embedded in the expandable material.

21. A method as in claim 1 wherein the carrier includes at least one appendage having at least two appendage surfaces and expandable material is selectively disposed on less than all of the appendage surfaces for achieving directional control over expansion of the expandable material.

22. A method as in claim 1 wherein the expandable material is extruded through an extruder selected from a single-screw extruder, a twin-screw extruder or a mini-applicator to dispose the expandable material on the carrier material.

23. A method as in claim 1 wherein the carrier or the fastener is at least partially formed of an adhesive, an encapsulated adhesive, a magnetic material or a combination thereof.

24. A method as in claim 1 wherein the expandable material volumetrically expands to a size that is at least 3000% its original size upon exposure to elevated temperatures.

25. A 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. A 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, or a sound absorption characteristic.

27. A method as in claim 1 wherein each sealing or baffling member includes extension of the carrier or fastener or a panel of material overlaying the expandable material, the extension or panel being in opposing relation to the expandable material for assisting in guiding the direction of expansion of the expandable material.

28. A method of forming a member for providing sealing or baffling to a structure, the method comprising:

providing a carrier material to an extrusion die, the carrier material being an elongated strip of polymeric material;

extruding an expandable material onto the carrier material;

forming the carrier material and the expandable material into a sealing or baffling member having a carrier and the expandable material disposed thereon; and

providing a fastener connected to the carrier;

wherein the expandable material volumetrically expands to a size that is at least 2000% its original size upon exposure to elevated; and

wherein:

i. the step of forming the members includes cutting the carrier material, or the expandable material or to form the sealing or baffling member;

ii. the structure is part of an automotive vehicle; and

iii. upon expansion of the expandable material, the expandable material forms a foam that substantially entirely spans the entirety of one or more cross-sections of the cavity of the structure to prevent the passage of debris, water, sound, air or a combination thereof through the cavity.

29. A method as in claim 28 wherein the step of forming the carrier material and the expandable material into the member includes cutting the carrier material and the expandable material to form the member.

30. A method as in claim 28 wherein the carrier material is provided as a strip or film of material that is co-extruded with the expandable material for disposing the expandable material upon the carrier material.

31. A method as in claim 28 wherein the expandable material is disposed upon the carrier material by cross-head extrusion.

32. A method as in claim 28 wherein the carrier material is extruded simultaneously with the expandable material, the carrier material is extruded prior to the extrusion of the expandable material upon the carrier material or the carrier material is coextruded with the expandable material and the resulting coextrusion is further extruded to form a desired profile configuration.

33. A method as in claim 28 wherein at least one end portion of the carrier is embedded in the expandable material.

34. A method as in claim 28 wherein the expandable material volumetrically expands to a size that is at least 3000% its original size.

35. A method of forming a member for providing sealing or baffling to a structure, the method comprising:

providing a carrier material to an extrusion die, the carrier material being an elongated strip of polymeric material;

extruding an expandable material through the extrusion die such that the expandable material contacts and adheres to the carrier material, the expandable material being shaped by the extrusion die;

forming the carrier material and the expandable material into members, each of the members having a carrier formed of the carrier material with the expandable material disposed thereon, each of the carriers having an edge disposed within the expandable material;

providing a mechanical fastener connected to the carrier by extending the mechanical fastener through a through-hole in the carrier; and

locating at least one of the members in the structure;

wherein the expandable material volumetrically expands to a size that is at least 3000% its original size upon exposure to elevated temperatures; and

wherein:

i. the step of forming the members includes cutting the carrier material and the expandable material to form individual members;

ii. the structure is part of an automotive vehicle; and

iii. upon expansion of the expandable material, the expandable material forms a foam that substantially entirely spans the entirety of one or more cross-sections of a cavity of the structure to prevent the passage of debris, water, sound, air or a combination thereof through the cavity.

36. A method as in claim 35 wherein the expandable material is disposed upon the carrier material by cross-head extrusion.

37. A method as in claim 35 wherein the expandable material is formed of a polymeric formulation that includes an acrylate, an acetate, an elastomer or a combination thereof.

38. A method as in claim 35 wherein each of the members has a length with both the carrier material and the expandable material extending along the length and wherein the length of at least one member extends along a length of the cavity prior to expansion of the expandable material.

39. A method as in claim 35 wherein the expandable material is an EVA/rubber based material.

40. A method as in claim 35 wherein the expandable material includes a reinforcement filler selected from carbon fibers, glass fibers, nylon fibers or aramid pulp.

41. A method as in claim 35 wherein the expandable material is dry to the touch.

42. A method as in claim 35 wherein:

i. the expandable material includes an acrylate;

ii. each of the members has a length with both the carrier and the expandable material extending along the length and wherein the length of the at least one member extends along a length of the cavity prior to expansion of the expandable material;

iii. the expandable material is an EVA/rubber based material;

iv. the expandable material includes a reinforcement filler selected from carbon fibers, glass fibers, nylon fibers or aramid pulp; and

v. the expandable material is dry to the touch.

43. A method as in claim 42 wherein the expandable material expands to span the one or more cross-sections transverse to the length of the at least one of the members.