Noise reduction member and system

1. A noise reduction system, comprising:

a structure of an automotive vehicle;

a noise reduction member located within the cavity of the structure, the noise reduction member including:

i. a carrier member having a top wall, a bottom wall, and a third wall, the top wall and bottom wall each including a securement flange extending therefrom;

ii. a mass of expandable material formed as a polyhedron and having a plurality of walls and located adjacent the top wall so that during expansion at least two sides of the mass will be substantially free of any contact with any wall of the carrier member; and

iii. an attachment integrally formed with the carrier member, both the attachment and carrier member formed of a polymeric material and locating the noise reduction member relative to the structure;

wherein upon expansion of the expandable material:

i. the top wall, upon expansion of the mass of expandable material, shields the expandable material from forming a foam material in a space adjacent the structure;

ii. the mass of expandable material expands to form a foam that occupies a volume that is at least 500% of the volume occupied by the original unexpended mass of expandable material;

iii. the third wall includes opening through which the foam flows during expansion to maximize filling of the structure; and

iv. the securement flanges extend into the material.

2. A system as in claim 1 wherein the structure includes an opening and the expandable material is prohibited from forming a foam material covering the opening due to the walls of the noise reduction member.

3. A system as in claim 1 wherein the mass of expandable material expands to form a foam that occupies a volume that is at least 2000% of the volume occupied by the original unexpended mass of expandable material.

4. A system as in claim 1 wherein, upon expansion, the expandable material substantially entirely fills a section of a cavity of the structure in which the member has been placed and forms a foam that spans across a cross-section of the cavity for inhibiting the passage of mass and sound through the cavity.

5. A system as in claim 1 wherein one of the top and bottom walls is located adjacent an opening of the structure for, upon expansion of the mass of expandable material, shielding the expandable material from forming a foam material that covers the opening.

6. A system as in claim 1 wherein the top wall is substantially parallel to the bottom wall.

7. A system as in claim 1 wherein the volume of the mass of expandable material is greater than about 1 cm 3 but less than about 2 cm 3 prior to expansion.

8. A system as in claim 1 wherein the expandable material is a heat activated thermosetting material that foams, expands and cure upon exposure to temperature in an e-coat or bake oven.

9. A noise reduction system, comprising:

a structure of an automotive vehicle;

a noise reduction member located within the cavity of the structure, the noise reduction member including:

i. a carrier member having a top wall, as bottom wall, and a third wall, the top wall and bottom wall each including a securement flange extending therefrom;

ii. a mass of expandable material formed as a polyhedron and having a plurality of walls and located adjacent the top wall so that during expansion at least two sides of the mass will be substantially free of any contact with any wall of the carrier member, the material being located in contact with each securement flange; and

iii. an attachment integrally formed with the carrier member, both the attachment and carrier member formed of a polymeric material and locating the noise reduction member relative to the structure;

wherein upon expansion of the expandable material:

i. the top wall, shields the expandable material from forming a foam material in a space adjacent the structure; and

ii. the mass of expandable material expands to form a foam that occupies a volume that is at least 500% of the volume occupied try the original unexpended mass of expandable material;

iii. the third wall includes a opening through which the foam flows during expansion to maximize filling of the structure; and

iv. the securement flanges extend into the material.

10. A system as in claim 9 wherein the volume of the mass of expandable material is greater than about 1.5 cm 3 but less than about 4 cm 3 prior to expansion.

11. A system as claim 9 wherein the top wall is substantially parallel to the bottom wall and the top and bottom wall are substantially perpendicular to the third wall.

12. A system as in claim 9 wherein the mass of expandable material expands to form a foam that occupies a volume that is at least 2000% of the volume occupied by the original unexpanded mass of expandable material.

13. A system as in claim 9 wherein, upon expansion, the expandable material substantially entirely fills a section of a cavity of the structure in which the member has been placed and forms a foam that spans across a cross-section of the cavity for inhibiting the passage of mass and sound through the cavity.

14. A system as in claim 9 wherein the mass of expandable material is located substantially entirely in the cavity of the carrier member, extending along an elongated axis and wherein:

i) the mass of expandable material is substantially entirely located between the top wall and the bottom wall;

ii) the mass of expandable material is generally shaped as the polyhedron having sides that are square, rectangular or both; and

iii) the mass of expandable material is configured to volumetrically expand to a volume that is at least 3000% of its original unexpanded volume.

15. A noise reduction system, comprising:

i. a carrier member having:

a. a top wall and a bottom wall, the top wall and bottom wall interconnecting with a side wall at top and bottom intersection points to define a cavity;

b. a securement flange;

ii. a mass of expandable material formed as a polyhedron and having a plurality of walls so that during expansion at least two walls of the mass will be substantially free of any contact with any wall of the carrier member;

iii. a fastener integrally molded with the carrier member extending into and through an opening of the vehicle structure for attaching the carrier member to the vehicle structure, wherein the fastener is located in between the top and bottom intersection points;

wherein the top wall, bottom wall, side wall, securement flange and fastener of the carrier member are integrally formed of a polymeric material and wherein the top wall, bottom wall and securement flange assist the expandable material in forming cavities that provide space both above and below the carrier member so that any openings in the vehicle structure located in these cavities will not be covered by the expandable material and will remain useful for allowing components to extend into and through the openings such that the size of the cavities formed by the to wall, the bottom wall and the expandable material depends on the length of the top wall, and bottom wall.