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[004] In a first aspect the present teachings contemplate a device comprising a unitary structure including a sealing body and a fastener integrated with the sealing body. The sealing body may include a plurality of surfaces formed from a non-rigid expandable material. The fastener may comprise a rigid material that is dissimilar from any material fo forming the sealing body.

[005] The sealing body may be substantially free of any rigid material Preferably, -the: sealing body consists essentially of an expandable material. The unitary structure may be formed by an injection molding or extrusion process. The sealing body may extend in a linear direction from a terminating end of a shank portion of the fastener such that the diameter of the sealing body is substantially similar to the diameter of the shank. The expandabi material of the sealing bod may be a tacky material and may include a removable film layer to allow for handling. The sealing body may be substantially rectangular in shape and may include at least four surfaces.

[006] The fastener may be a tree fastener. The fastener may include a cap portion and shank portion such that the diameter of the cap exceeds the diameter of the shank so that the diameter of the ca prevents com lete pui (-through of the fastener through an opening in a cavity wa!i. The fastener may include a central portion into which the sealing body extends. The central portion of the fastener may he In .direct planar contact with at least two surfaces of the sealing body; At least two surfaces of the sealing body may be substantially free of any contact with the fastener. The fastener may include a central portion along the shank, the central portion including a void for receiving at least a portion of the sealing body. A portion of the sealing body m y e located within th void of the central portion so that the sealing body is located adjacent one or more wings located along the shank. The width of the portion of the sealing body located within the. void may be less than the width of any portion of the sealing body that is not within the void. An edge of the ^■■ sealing body may fas substantially parallel to the one or more wings of the fastener. The void within the central portion of the fastener ma include a bridge portion that contacts first wall and an opposing second wail of the shank, The bodg portion ma be substantially surrounded by the expandable material of the sealing body,

pQ7] The present teachings further contemplate a method comprising extruding a fastener portion from a rigid material and extruding a sealing body portion from a non-rigid expandable material onto the fastener portion to form a unitary structure. The fastener may include a central portion having void and the expandable material of the sealing body is received within the void during the extrusion process. The sealing body may be extruded about the f stener so that it extends in a linea direction f om a terminating end of a shank portion of the fastener such that the diameter of ai least a portio of the sealing body Is substantially similar to the diameter of the shank portion,

£008! T e teachings herein contemplate device and method for the baffling and/or sealing of cavities with an expandable- sealing bod including one or more integrated fasteners. The expandable sealing body and integrated fastener disclosed herein may allow for effective baffling and/or sealing of a cavity with a lightweight structure with no need for additional fastening means. The device disclosed herein may further allow for simplified insertion into cavities where access is minimal, such that the device can be located within the cavity through: relatively small openings (e.g., openings having a diameter smaller than that of the- fastener),

|009] Fig, 1 shows a top-down view of an illustrative example of. the sealing body and fastener of the present teachings.

[0(510] Fig. 2 shows a side profile view of the sealing body and fastener of Fig. t.

.{0011 j Fig. 3 shows a perspective view of the fastener shown at Fig. 1 and 2. [001 ] ^' Fig. 4 shows an additional perspective view of the fastener shown at Fig. 1 and 2 showing interna! features of the fastener.

[001.3] The present teachings allow for improved baffling and sealing of a cavit with a lightweight sealing body and Integrated fastener. The unitary structure disclosed herein may include an expandable sealing bod and integrated fastener. Th integrated fastener may he comprised of a rigid material that is dissimilar to that of the sealing of the sealing body. The sealing body ma comprise or may consist essentially of a non-rigid expandable material The sealing body and integrated fastene may be infection molded or extruded to form a unitary device. The sealing body and integrated fastener may be co-injection molded or co- extruded to f orm a unitar device.

[0014] The sealing body may be substantially free of any rigid material. Preferably, the sealing body consists essentially of an expandable mate rial. The sealing body may be formed so that a portion of the sealing body lies In direct planar contact with a portion of the fastener. The sealing body may form a mechanical connection with the fastener. The portio of the sealing body located in contact with the fastener may be adhered to the fastener via an adhesive. The portion of the sealing body located in contact with the fastener may be adhered to the fastener by a tacky nature of the expandable material that forms the sealing body. The sealing body and fastener may be adhered to one another during an extrusion process. The sealing body and fastener may be adhered to one another during an injection molding process. The connection between the sealing body and fastener may be of sufficient strength so that when the fastener is located info an opening in a cavity wail, the sealing body and fastener remain connected at least until the expandable material undergoes expansion.

[0015] The sealing bod may extend in a substantially linear direction from a terminating end of a shank portion of the fastener such that the diameter of the sealing body is substantially similar to the diameter of the shank, Alternatively, the sealing body may fake on any shape or extend in any direction that avoids disengagement from the fastener prior to expansion and does not cover openings In the cavity wail or prevent the cavity wall from receiving necessary coatings prior to expansion. However, the selection of the shape and size of the sealing bod may be such that the sealing body can be located into a cavity through an opening in the cavity that receives the fastener. In other words, the sealing device as described herein is particularl useful when access to a cavity is permitted only through an opening in the cavity wail that is smaller than the maximum width Of the fastener (e.g.,. the largest wicith of the fastener which may be at the ca portion of the fastener). [0018] The sealing body may be substantially rectangular- in shape and may include at least four surfaces. The length of the sealing bod may be at least tw times., at least 4 times, or event at least 10 times the width of the sealing body. The width of the sealing body (prior to expansion) may fee less than the width of the fastener at its widest point (e.g., the width of the cap portion}. The sealing body may be substantially rectangular in shape such that it includes two sets of opposing walls and a plurality of substantiall perpendicular walls, The sealing body may be of any polygonal shape. The sealing body may have curved walls and/or may be substantially circular in shape.

[0017] The expandable material of the sealing body may be a tacky material and may include a removable fil layer to allow for handling. The tack nature of the sealing body may promote adhesion between the sealing body and fastener,. Alternatively, the expandable material may be substantially dry to the touch.

[0018] The fastener may be a tree fastener. The fastener may b a push-pin fastener. The fastener may be a trapezoidal push-pin fastener. The fastener may be fastener as disclosed in U.S. Patent No, 8,029.222, incorporated by reference herein for ail purposes. The fastener ma Include a cap portion and shank portion such that the diameter of the cap exceeds the diameter of the shank so that the diameter of the cap prevents complete pull- through of the fastener through an opening In a cavity wail. Th shank may include ^' a first wall and an opposing second wall. Between the first and second wall, the fastener may Include a central portion into which the sealing body extends. The central portion of the fastener may include a void for receiving at least a portion of the sealing body. The central portion of the fastener may be in direct planar contact with at least two surfaces of the sealing body. At least two surfaces of the sealing body ma be substantially free of an contact with the fastener. The fastener (e.g„ the shank of the fastener) ma include, one or more wings, one or more of which may engage a cavity wall surrounding ah opening i the cavity , wail. The wings may be located at evenly spaced about intervals along the shank of the fastener. The wing may be located along one surface of the fastener, along two surfaces of the fastener, or along three or more surfaces of the fastener. A portion of the sealing body may be located within the void of the central portion so that the sealing body is located adjacent one: or more wings ^' located. along ^' the .shank. The width of the portion of the sealing body located within the void may be less than the width of any portion of the sealing body that is not within the void. An edge of the sealing body (which may be a Terminating edge) may be substantially parallel to the one or more wings of the fastener.

[0019] The void within the central portion of the fastener may include a bridge portion that contacts the first wall and the opposing second wail of the shank. The bridge portion ma be substantially surrounded by ^" the expandable material of the sealing body. The bridge portion may he formed of _. a rigid material The bridge portion may be integrally formed with the fastener of the same rigid material as the fastener. The bridge portion may act to create: a mechanical interlock between the sealing body and fastener and as such may include one o more openings w ich receives a portion of the the expandable . ^' material of the sealing body during formation of the device.

[0020] The resent teachings further contemplate a method comprising extruding a fastener portion from a rigid material- and extruding a sealing body portion from a non-rigid expandable material onto the fastener portion to form a unitary structure. The fastener may include: a central portion having a void and the expandable material of the sealing body Is received within the void during the extrusion process. The sealing body may be extruded about the fastener so that it extends in a linear direction from a terminating end of a _. shank portion of the fastener such that the diameter of at least a portion of the sealing body is substantially similar to the diameter of the shank portion. .Alternatively, the method may comprise molding a fastener portion from a rigid material and molding a sealing body portio from a non-rigid expandable maier ai onto the fastener portion to form a unitary structure. The fastener may include a oentrai portion having a void and the expandable material of the sealing body is received within the void during the molding, process. The seating body may be molded about the fastener. The sealing body may he molded about the fastener so that it extend in a linear direction from a terminating end of a shank portion of the fastener such that the diameter of at least a portion of the sealing body is substantially similar to the diameter of the shank portion.

.[0021] The expandable sealing body and integrated fastener ma also include, an adhesive laye that comprises an outer surface of the expandable sealing body and integrated fastener. The expandable sealing body and integrated fastener may include plurality of sides with varying lengths, the lengths of some sides being substantially longe than the lengths of other sides. The sealing body and integrated fastener, the cut-outs, or both may be; substantially rectangular in shape.

[0022] The materials may also include a film layer, such as that disclosed in U.S. Patent- Publication Nos. 2004/0076831 and 2005/0260390, incorporated by reference herein for ail purposes. The film, layer may he used to cover a material that i tacky to the touch. The film layer may be removed from th material prior to application of the material to a vehicle structure, such that the film will reveal a tacky surface of the material that will adhere to the structure.

[0023] The size of the expandable sealing body and integrated fastener ma depend upon th size of the opening through which the expandable sealing body and integrated fastener is located, The thickness of the expandable sealing body may he at least about 0.1 mm. The thickness of the expandable sealing body may be less than about 50mm. The: thickness of the expandable sealing body may b from about 0.5mm to about 20mm. The thickness of the expandable sealing body may be lass than about: 10mm. The thickness of the expandable sealing body may be from about 3mm to about 8mm. The length of the expandable, sealing body ma be any lengt required to sufficiently .fill cavity:, As an example, the length of the expandable sealing body may foe at least about 5mm, at least about 2Grnm or even at least about 50mm.

[0024] After placement of the expandable sealing body and Integrated fastener through an opening (and optionally into a cavity), the expandable material ma expand according to a predetermined set of conditions. For example, exposure to certain levels of heat may cause the expandable material to expand. The volumetric expansion of the expandable materia! may vary depending upon the sealing and/or baffling needs of particular cavity. The expandable sealing body and integrated fastener may expand at least about 100%, The expandable material may expand Jess than about 2,000%. The expandable material may expand at least about 500%, at least about 1,000%, or more. The expandable material may expand less than about 1,000% or even less than about 500%.

[0025] The expandable sealing body may be generally dry to .the touch or tacky and may be shaped in an form of desired pattern, placement, or thickness, but is preferably of substantially uniform thickness, Though other heat-activated materiais ar possible for the expandable sealing body and integrated fastener, a preferred heat activated material is an expandable polymer or plastic, and preferably one that is foa able, The expandable sealing body and integrated fastener may be a relatively high expansion loam having a polymeric formulation that includes one or more of an .epoxy resin, an acetate (e.g. ethylene vin l acetate), a . thermoplastic, po!yether, an aerySate and/or a methacrylate (e,.g., a copolymer of butyl acrylate and methyl acryfate), an ©poxy/elastomer addue , and one or more fillers (e.g., a clay filler, and/or a nanoparticie-confaining filler):. Preferred thermally expandable materials are disclosed in U.S. Patent Nos. 7,313,885; 7,125,461; and 7,199,185, incorporated by reference herein for ait purposes. For example, and without limitation, the foam may also be an EVA/rubbef based material including a ethylene copolymer or ferpolymer that may possess an aipha-oiefin . As a copolymer or ferpolymer, the polymer is composed of two or three different monomers, i.e., small molecules with high chemical reactivity that are capable of linking up with similar molecules. Suitable expandable materials include those -.available from L&L Products, inc. under the designation -17220, L2821, 11066, 1205, J_2010, 12108, _. L2108A, L2808, 12811, 14200, L4141, L4181 , L4315, LS510, LS520, L5540, L560Q, L5601, L7102, and L7104. The expandable sealing body may be -die, cut material

[OOSSj A number of baffling or sealing foams may also be used for the expandable sealing body and Integrated fastener. A typical foam includes a polymeric base material, such as one or more ethy!ene-based polymers which, when compounded -with appropriate Ingredients (typically a blowing and curing agent), will expand and cure in a reliable and

8 predictable manner upon the application of heat or the occurrence of a particular condition., From a chemical standpoint for a thermally-activated material, the foam is usually initially processed as a fl wab!e material before curing, and upon curing, the materia! vsrfil topically cross-link making the materia! incapable of further flow,

[0027] The expandable sealing body can be formed of other materials provided that the materia! selected is heat-activated or otherwis activate by an ambient conditio (e.g. moisture, pressure, time or the like) and cures under appropriate conditions for the selected application. One such material is the epoxy based resi disclosed in U.S. Patent No. 8,131 ,897, .the teachings of which are incorporated herein by reference. Some other possible: materials include, but are not limited to, poiyoiefin materials, copolymers., and terpolymers with at least one monomer type such as an aipha-olefin, phenol/formaldehyde materials, phenoxy materials, and po!vurethane materials with high glass transition temperatures. Additional materials may also be used such as thos disclosed in U.S. Patent Nos. §,766,719; 5,755,486", 5,575,523; and 5,932,880, incorporated by reference herein for all purposes.

[0028] in applications- where the expandable sealing body comprises a heat activated material, an important consideration involved with the selection and formulation of the material is the temperature at which a material cures and, if expandable, the temperature of expansion, Typicaiiy, the material becomes reactive feures, expands, or both) a higher processing temperatures, such as those encountered in an automobile assembly plant, when the material is processed along with the automobile structures at elevated temperatures or at higher applied energy Seveis, e.g., during coating (e.g., e-coat paint, or ciearcoat) curing steps. While temperatures encountered In an automobile assembly operation may he in the range of about 148,Θ9¾ to 204,44 ^e C (about 3QCTF to 400*F) for body sho applications (e.g., e-eoatj and, for paint shop applications, are commonly about S3.33¾ (about 200 } or slightly higher (e.g., 120 ^a C to 150°C).

[0029] The expandable sealing body and integrated fastener may be mechanically attached to a cavity wail via the integrated fastener. The integrated fastener may be shaped as a tree- fastener, an arrow-head fastener,- or a threaded fastener. The Integrated fastener may a!so be formed In a variety of shapes and in a variety of configurations so long as it can secure the expandable sealing body to a cavity. The integrated fastener may be formed of rigid material, which may be a metal or polymeric material. The integrated fastener may be formed of a nylon material The integrated fastener may be capable --of securing multiple layers or types of materials to a structure. The integrated fastener ma be capable of receiving an additional fastening means located thereon after the fastener has been located into an opening. The integrated fastener may be shaped as a partial arrowhead fastener. The integrated fastener may have flexible wings such as that disclosed In U>S. Patent o. 8,029,222 (incorporated by reference herein for aii purposes), so that if can be located into an opening having a ^' diameter that is smaller than the largest diameter of the fastener, 10030] ^' The- expandable sealing body and integrated fastener of the present invention .may be installed into an automotive vehicle although it may be employed for othe articles of manufacture such as beats, buildings, furniture, storage containers or. the like. The expandable sealing body and integrated fastener may be used to seal and/or baffle a variety of components ^' of an automotive vehicle including., without limitation, body components {e,g., panels), frame components (e.g., hydroformed tubes), pillar structures {e.g., A, B, C or D~ piiSars), bumpers,, roots, bulkheads, instrument panels, wheel -wells, floor pans, door beams., hem flanges, vehicle betiline -applications,: doors, door sills, rockers, dec ds, hoods or the: like of the automotive vehicle.

[0031 ) The materials and formation process of the present Invention create a sim lified lightweight sealing, reinforcement, ^" and baffling device that can be easily customised to fit an cavity. The integrated fastener may be molded onto the sealing body.

[0032] As shown for example i Fig, 1 and 2, the device (e.g., the: unitary structure) 10 ma include a sealing foody 12 and integrated fastene 4. The integrated fastene 14 may include a cap portion 6 a d shank portion 18. The integrated fastener may include a plurality of wings 20,. The sealing body has a length (I), a width (w) and a thickness ft).

[0033] .As shown in Figs, 3 and 4, the integrated fastener 1-4 may Include a cap portion 18 and shank portion 18. The diameter (dl) of the cap portion may be larger than any diameter (d2) of the shank portion. The sealing body 12 may be unitarijy formed with the integrated fastener 1 suc that a portion of the sealin bod 22 lies in direct planar contact with a portion of the integrated fastener 24.

[0034] Any numerical values recited herein include all values from the Sower value to the upper value in increments of one unit provided thai there is a separation of at least 2 units between any lower value and any higher value. As an example, if it is stated thai the amount of a componen or a value of a process variable such as, for example, temperature, pressure, time and- the like, is, for example, from 1 to 90, preferably from 20 to 80, more preferably from 30 fo 70, it Is intended that values such as 15 to 85, 22 to 88, 43 to SI, 30 to 32 etc, are expressly enumerated in this specification. For .values which are less than one, one unit is considered to b ^' e 0,0001, 0,001. 0.01, or 0.1 as appropriate. These are only examples of what is specifically intended and ail possible ^■ combinations of numerical values between th lowest value and the highest value enumerated are to be considered to be expressly stated in this application In a similar manner. As can be- -seen, the teaching of amounts expressed as "parts by weight ^" ' herein also contemplates the same ranges expressed in terms of percent by weight. Thus, an expression in the: Detailed Description of the Invention of a range in terms of at * ^* £ parts by weight of the- resulting polymeric blend composition' ^' also contemplates- a teaching of r nges f same recited amount of ^* x* in percent by weight of the resulting polymeric blend composition.' ¹

[0035] .Unless: .otherwise stated, all ranges include both endpoints and all numbers between the endpoints. The use of "about ^* or "approximately" in connection with a range applies to both ends of the range. Thus, "about 20 to 30" is intended to cover "about 20 to about 30", Inclusive of at least the specified endpoints.

0036] The disclosures of ail articles and references, including patent applications and publications, are incorporated by reference: for all purposes. The- term ^' "consisting -essentially of to describe a combination shall include the elements:, ingredients, components, or steps identified, and such other elements ingredients, components, or steps that do not materiall affect the basic and novel characteristics of the combination. The use of the terms "comprising" or Including ⁸ describe combinations of elements, ingredients, components, or steps herein also contemplates embodiments that consist essentially of the elements, Ingredients, components or steps. By use of the term "ma " herein, it is intended that any described attributes that ^" may" be included are optional.

[0037] Plural elements, ingredients, components or steps can be provided by a singl integrated element, ingredient component, or steps Alternatively, a single integrated element, ingredient, component, or step might be divided into separate plural elements, ingredients: components, or steps. The disclosure- of "a" or "one" to describe an element, ingredient, component, or step is no intended to foreclose additional elements, Ingredients, _, components, or steps.

[0038] It is understood that the above description is intended to be illustrative and not restrictive. Many embodiments: as well as many applications besides the examples provided will be apparent to those of skill in the art upon reading the above description. The scope of the invention should, therefore, he determined not with referenc to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims ate entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference fo all purposes.: The omission in the following claims of any aspect of subject matter that is disclosed herein is not a disclaimer of such subject matter, nor should it be regarded that th Inventors did not consider such subject matter to be part of the disclosed inventive subject matter.