Members for directing expandable material for baffling, sealing, reinforcing

A device comprising:

• a) a carrier having a predetermined shape to guide one or more expansion directions of an injection molded expandable material, the carrier having one or more hinge portions, wherein the one or more hinge portions include an indent on a first surface of the carrier;
• b) the injection molded expandable material on a second surface of the carrier opposing the first surface, the expandable material having a notch formed therein, wherein the notch directly opposes and aligns with the indent,
• wherein the notch and the indent are located along a longitudinal axis of the carrier;
• wherein the expandable material is formed on the carrier at one or more angles perpendicular to the one or more expansion directions;
• and
• wherein the expandable material is capable of being activated to expand under an activation condition to come into contact with and adhere to one or more walls defining a cavity in order to at least partially fill the cavity.