Patent ID: 9718240
Date: 2017-08-01
CPC Classifications: B29C,B62D

Claim:
1. A method comprising: extruding an expandable material to have a particular cross-sectional profile; inserting the expandable material into a molding tool; shaping the expandable material within the molding tool; and overmolding a carrier material onto a portion of the expandable material within the molding tool, wherein the overmolding step includes injecting the carrier material into the molding tool at a temperature above a melting temperature of the expandable material, wherein the molding tool includes a plurality of openings for receiving the expandable material, and the expandable material is inserted into each of the plurality of openings, wherein the plurality of openings includes at least four openings, and wherein the expandable material is inserted into each of the at least four openings.