Patent ID: 8276974

Claim:
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.