Patent ID: 8535463
Filing Date: 2013-09-17
Classification: B60R,B62D,G10K,Y10T

Abstract:
1. A method of making an uncured acoustic absorbing member, comprising inserting a carrier into a mold, closing the mold and overmolding the carrier in the mold by introducing a softened or molten thermally expandable material into the mold while maintaining the temperature of the thermally expandable material below a temperature at which it expands, and then cooling the thermally expandable material, wherein; (i) the carrier includes a wall portion having first and second opposing sides and openings extending through the wall portion from the first opposing side to the second opposing side, wherein said openings have a width of from 0.5 to 20 mm and wherein said openings constitute in the aggregate from 10 to 85% of the surface area of the wall portion, and further wherein the first and second opposing sides of the carrier include raised areas such that the thickness of the carrier is equal to the thickness of the closed mold; the thermally expandable material is applied to both of said opposing sides of the carrier; said openings in the carrier are not filled by the thermally expandable material and; the thickness of the layers of the thermally expandable material is approximately equal to the height of the raised areas above the respective opposing sides of the carrier.