Synthetic material and methods of forming and applying same

• US 20040033344A1
• Filed: 08/13/2002
• Published: 02/19/2004
• Est. Priority Date: 08/13/2002
• Status: Active Grant

• Current Assignee: Zephyros, Inc.
• Original Assignee: L&L Products Inc.
• Inventors: Czaplicki, Michael J., Madaus, Keith
• Granted Patent: US 6,811,864 B2
• Time in Patent Office: Days
• US Class Current: 428/202
• CPC Class Codes: B05D 7/02 to macromolecular substances, e.g. rubber treatment or coating of shaped articles made of macromolecular substances C08J7/00
• CPC Class Codes: B32B 25/00 Layered products comprising a layer of natural or synthetic rubber fibrous or filamentary layer made of a natural or synthetic rubber B32B5/02; particulate layer made of a natural or synthetic rubber B32B5/16; foamed layer made of a natural or synthetic rubber B32B5/18
• CPC Class Codes: C08J 2207/02 Adhesive
• CPC Class Codes: C08J 5/12 Bonding of a preformed macromolecular material to the same or other solid material such as metal, glass, leather, e.g. using adhesives
• CPC Class Codes: C08J 9/365 Coating
• CPC Class Codes: C09J 2463/00 Presence of epoxy resin
• CPC Class Codes: C09J 7/22 Plastics; Metallised plastics
• CPC Class Codes: C09J 7/35 Heat-activated
• CPC Class Codes: C09J 7/38 Pressure-sensitive adhesives [PSA]
• CPC Class Codes: Y10T 428/2486 with outer strippable or release layer
• CPC Class Codes: Y10T 428/249982 With component specified as adhesive or bonding agent
• CPC Class Codes: Y10T 428/249983 As outermost component
• CPC Class Codes: Y10T 428/249985 Composition of adhesive or bonding component specified
• CPC Class Codes: Y10T 428/31511 Of epoxy ether
• CPC Class Codes: Y10T 428/31663 As siloxane, silicone or silane
• CPC Class Codes: Y10T 428/31725 Of polyamide
• CPC Class Codes: Y10T 428/31736 Next to polyester
• CPC Class Codes: Y10T 428/3175 Next to addition polymer from unsaturated monomer[s]
• CPC Class Codes: Y10T 428/31757 Polymer of monoethylenically unsaturated hydrocarbon
• CPC Class Codes: Y10T 428/31761 Next to aldehyde or ketone condensation product
• CPC Class Codes: Y10T 428/31786 : Of polyester [e.g., alkyd, etc.]
• CPC Class Codes: Y10T 428/31797 : Next to addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31826 : Of natural rubber
• CPC Class Codes: Y10T 428/3183 : Next to second layer of natural rubber
• CPC Class Codes: Y10T 428/31833 : Next to aldehyde or ketone condensation product or addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31855 : Of addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31877 : Phenol-aldehyde
• CPC Class Codes: Y10T 428/31913 : Monoolefin polymer

Abstract

A synthetic material and articles incorporating the same are disclosed. The synthetic material includes a base material, which is at least partially tacky. Preferably, a powder is dispensed upon the base material for providing a substantially non-tacky surface to the synthetic material.

Claims

1. A synthetic material comprising:

a base material that is tacky at a temperature of less than about 80°

C., the base material providing at least one tacky surface; and

a powder layered upon the base material, the powder providing a substantially non-tacky surface at a temperature of up to about 40°

C., the powder exhibiting adhesivity at a temperature greater than 120°

C.

2. A synthetic material as in claim 1 wherein the base material is selected from the group consisting of a thermoplastic-based material, an epoxy-based material and an elastomer based material.

3. A synthetic material as in claim 1 wherein the powder includes one or more correspondence components.

4. A synthetic material as in claim 3 wherein the one or more correspondence components are substantially identical to one or more components in the base material.

5. A synthetic material as in claim 4 wherein at least one of the one or more correspondence components is an epoxy material.

6. A synthetic material as in claim 5 wherein the one or more correspondence components represent 30% by weight of the powder.

7. A synthetic material as in claim 5 wherein the one or more correspondence components represent 60% by weight of the powder.

8. A synthetic material comprising:

a base material that is tacky at a temperature of about 23°

C. wherein;

i) the base material is epoxy-based; and

ii) the base material provides at least one tacky surface; and

a powder layer on the base material wherein;

i) the powder provides a substantially non-tacky surface at a temperature of about 23°

C.;

ii) the powder exhibits adhesivity at a temperature greater than 120°

C.; and

iii) the powder includes at least one or more epoxy correspondence components.

9. A synthetic material as in claim 8 wherein the one or more epoxy correspondence components are substantially identical to one or more components in the base material.

10. A synthetic material as in claim 9 wherein the one or more correspondence components represent 30% by weight of the powder.

11. A synthetic material as in claim 10 wherein the one or more correspondence components represent 60% by weight of the powder.

12. A method of reinforcing or providing acoustical damping to a member of an article of manufacture with a synthetic material comprising:

providing a base material, the base material including primarily epoxy components, the base material being tacky at a temperature of about 23°

C.;

providing a powder, the powder including primarily epoxy based correspondence components, the powder being substantially non-tacky at a temperature of about 23°

C., the powder exhibiting adhesivity at a temperature greater than 80°

C.;

dispensing the powder upon the base material to form the synthetic material with at least one substantially non-tacky surface and at least one tacky surface; and

applying the synthetic material to the member of the article of manufacture.

13. A method as in claim 12 wherein the step of applying the synthetic material includes contacting the non-tacky surface of the synthetic material such that the tacky surface of the synthetic material is adhered to the member.

14. A method as in claim 13 further comprising, applying release paper to the tacky surface of the synthetic material.

15. A method as in claim 14 wherein the step of applying the synthetic material to the member also includes removing said release paper from said synthetic material.

16. A method as in claim 15 wherein the article of manufacture is an automotive vehicle and the member is selected from the group consisting of a frame member and a body member of the automotive vehicle.

17. A synthetic material as in claim 16 wherein the one or more correspondence components are substantially identical to one or more components in the base material.

18. A synthetic material as in claim 17 wherein the one or more correspondence components represent 30% by weight of the powder.

19. A synthetic material as in claim 17 wherein the one or more correspondence components represent 60% by weight of the powder.