Patent ID: 7249415

Claim:
A method of forming members for providing sealing or baffling to one or more structures, the method comprising: providing a carrier material; disposing an expandable material upon the carrier material in a continuous manner; forming sealing or baffling members such that each of the members includes a carrier with the expandable material disposed thereon, the carrier being formed of the carrier material; and providing a fastener connected to the carrier; wherein the expandable material volumetrically expands to a size that is at least 2000% its original size upon exposure to elevated temperatures; and wherein: i. the step of forming the members includes dividing the carrier material, the expandable material or both to form the sealing or baffling members; ii. the one or more structures are part of an automotive vehicle; and iii. upon expansion of the expandable material, the expandable material forms a foam that substantially entirely spans the entirety of one or more cross-sections of a cavity of the one or more structures to prevent the passage of debris, water, sound, air or a combination thereof through the cavity.