Method of forming fastenable member for sealing, baffling or reinforcing

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

extruding a carrier, the carrier including a longitudinal axis and at least one integrally formed clip on a first terminating end of the carrier, the clip configured to create an interference fit between the member and a wall of a structure;

co-extruding an expandable material onto only a second terminating end of the carrier that opposes the first terminating end of the carrier, which is capable of expansion to a volume of at least about 2000% of its original volume, wherein the expandable material has a substantially consistent rectangular shape and a substantially consistent thickness along an entirety of the carrier which receives the expandable material;

wherein the member includes one or more extensions, which are integrally attached to the carrier and extend into the expandable material, and wherein the integrally formed clip is free of any contact with the expandable material.

2. The method as in claim 1 , wherein the method includes cutting the carrier material and the expandable material to form individual members.

3. The method as in claim 1 , wherein the expandable material is disposed upon the carrier material by cross-head extrusion.

4. The method as in claim 1 , wherein the expandable material has adhesive properties and is adapted for forming a sealing material or an acoustical material.

5. The method as in claim 4 , 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.

6. The method as in claim 4 , wherein a portion of the integrally formed clip extends into an opening in the structure and forms an interference fit with the structure.

7. The method as in claim 1 , wherein the expandable material includes a polyolefin-containing plastic.

8. The method as in claim 1 , wherein the carrier is made of a polyamide or a metallic material.

9. The method as in claim 1 , wherein the carrier is elongated and the carrier profile of the member includes a portion that has a curved shape.

10. The method as in claim 1 , wherein, prior to expansion of the expandable material, at least about 10% of an outer surface area of the carrier of the member is covered with the expandable material.

11. The method as in claim 1 , wherein the carrier includes at least two integrally formed extensions extending away from a base portion of the carrier and into the expandable material.

12. The method as in claim 11 , wherein the profile of the member includes a portion that is curved.

13. The method of claim 1 , wherein the expandable material is extruded onto only a first surface of the carrier.

14. The method of claim 1 , wherein the thickness of the expandable material is at least twice the thickness of the carrier.

15. A method of forming a member for providing sealing or baffling to one or more structures, the method comprising:

extruding an elongated carrier, the carrier including a base portion having one or more extensions that extend away from a base portion of the carrier and an integrally formed clip located at a first terminating end of the carrier for attaching the member to a wall of a structure;

extruding an expandable material that includes a copolymer or terpolymer with at least one alpha-olefin monomer, which is capable of expansion to a volume of at least about 2000% of its original volume, onto a surface of the carrier in a continuous manner such that the expandable material has a substantially consistent profile and substantially consistent thickness along an entirety of the carrier surface which receives the expandable material;

wherein the expandable material is located on a second terminating end of the carrier that opposes the first terminating end of the carrier so that the integrally formed clip is free of any contact with the expandable material;

wherein the expandable material of the member includes an ethylene vinyl acetate polymeric material and is generally dry to the touch.

16. The method of claim 15 , wherein the expandable material is extruded to have a rectangular profile.

17. The method of claim 16 , wherein the expandable material is extruded as a single mass and no additional masses of expandable material are included on the carrier.

18. The method of claim 15 , wherein the expandable material is extruded as a single mass and no additional masses of expandable material are included on the carrier.

19. The method of claim 15 , wherein the expandable material is extruded onto only a first surface of the carrier.

20. The method of claim 15 , wherein the thickness of the expandable material is at least twice the thickness of the carrier.