Patent ID: 7941925

Claim:
A method of forming members for providing sealing or baffling to one or more structures of an automotive vehicle, the method comprising: providing an expandable material in a continuous manner, wherein: i) a flexible, film carrier material is provided in an elongated strip to an extrusion die in continuous manner and the expandable material is being emitted to the same extrusion die so that the expandable material intimately contacts and adheres to the elongated strip of the film carrier material; ii) the expandable material includes one, or more ethylene base polymers; and iii) the expandable material includes a blowing agent and a curing agent; forming the expandable material into a plurality of members by cutting the elongated strip of film carrier material and expandable material at predetermined lengths; and providing at least one fastener connected to each member of the plurality of members after formation of each member by forming openings in both the film carrier material and expandable material after extrusion; wherein: i) the expandable material activates to foam at temperatures typically experienced in automotive painting or coating operations; ii) the expandable material, upon activation, volumetrically expands to a size that is at least 1500% its original size; and iii) the each member of the plurality of members is manually connected to the at least one fastener.