Assembly of injection-molded carrier and insert(s) containing heat-expandable resin composition

A method of making an assembly comprising placing an insert within a receptacle contained in an injection-molded carrier comprised of a heat resistant thermoplastic, wherein the carrier has a first side and a second side, the insert is comprised of a heat-expandable resin composition, is cylindrical in shape and has a surface groove which extends at least partially around a circumference of the insert, the receptacle is adapted to receive and retain the insert, and the at least one receptacle contains at least one deflectable prong adapted to engage the surface groove of the insert and retain the insert in place within the receptacle.

A structurally reinforced and/or vibration/sound dampened hollow member, comprising a hollow member within which is present an assembly comprising an injection-molded carrier comprised of a heat resistant thermoplastic, wherein the carrier has a first side and a second side, with at least one of the first side or the second side having at least one receptacle within which is positioned a portion of an expanded resin composition, the portion of expanded resin composition extending from the receptacle and contacting an inner surface of the hollow member, and wherein the portion of expanded resin composition is obtained by heat-activation of an insert comprised of a heat-expandable composition which is cylindrical in shape and has a surface groove which extends at least partially around a circumference of the insert, the at least one receptacle containing at least one deflectable prong adapted to engage the surface groove of the insert and retain the insert in place within the receptacle.

An assembly comprising an injection-molded carrier comprised of a heat resistant thermoplastic composition, wherein the carrier has a first side and a second side, with a plurality of openings in at least one of the first side or the second side forming a grid or lattice, wherein one or more of the openings are adapted to receive and retain an insert comprised of a heat-expandable resin composition, the insert being cylindrical in shape and having a surface groove which extends at least partially around a circumference of the insert, and contain at least one deflectable prong adapted to engage the surface groove of the insert and retain the insert in place within the opening, and a mounting member adapted to fasten the carrier to an interior wall of a hollow member and hold the first side or second side of the carrier away from an exterior wall and away from and facing the interior wall.