Method of forming fastenable member for sealing, baffling or reinforcing

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

providing an expandable material and a carrier material;

co-extruding the expandable material and carrier material whereby the expandable material is extruded in a cylindrical profile onto and surrounding a substantially planar carrier portion of the carrier material prior to expansion of the expandable material;

providing a fastener connected to the carrier portion, the fastener including one or more extensions;

locating the expandable material into a vehicle cavity by placing the fastener through an opening in a cavity wall.

2. A method as in claim 1 wherein the step of forming the expandable material in a cylindrical shape includes cutting the expandable material to form individual members.

3. A method as in claim 1 wherein the expandable material is formed by cross-head extrusion.

4. A method as in claim 1 wherein the fastener is a mechanical fastener that is separately formed from the expandable material.

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

6. A method as in claim 1 wherein the expandable material is a material that is thermally deformable at a temperature of extrusion, but upon thermal activation at an elevated temperature will cross link to form a thermoset material.

7. 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.

8. A method as in claim 1 wherein at least a portion of the fastener is embedded in the expandable material.

9. 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.

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

11. A method as in claim 1 wherein the expandable material has a configuration that has a substantially uniform thickness.

12. The method of claim 1 , wherein the fastener is integrally formed with the carrier material.

13. The method of claim 1 , including a step of connecting the fastener to one or more of the carrier material, the expandable material, or both after co-extrusion of the expandable material and carrier material and cutting of the expandable material and carrier material.

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

providing an expandable material having a substantially uniform thickness and a carrier material;

co-extruding the expandable material and carrier material whereby the expandable material is extruded in a cylindrical profile onto and surrounding a substantially planar carrier portion of the carrier material prior to expansion of the expandable material;

providing a fastener connected to the carrier portion, the fastener including a plurality of extensions;

locating the expandable material into a vehicle cavity by placing the fastener through an opening in a cavity wall whereby at least two of the extensions are extended through the opening, the extensions being flexed toward one another until located through the opening and spread away from each other once through the opening to form an interference fit between the member and the cavity wall.

15. The method of claim 14 wherein the expandable material volumetrically expands to a size that is at least 3000% its original size up exposure to elevated temperatures.

16. The method of claim 14 , wherein the fastener is integrally formed with the carrier material.

17. The method of claim 14 , wherein the step of forming the expandable material in a cylindrical shape includes cutting the expandable material to form individual members.

18. The method of claim 14 , wherein the expandable material is a material that is thermally deformable at a temperature of extrusion, but upon thermal activation at an elevated temperature will cross link to form a thermoset material.

19. The method of claim 14 , wherein at least a portion of the fastener is embedded in the expandable material.

20. The method of claim 14 , including a step of connecting the fastener to one or more of the carrier material, the expandable material, or both after co-extrusion of the expandable material and carrier material and cutting of the expandable material and carrier material.