Synthetic material and methods of forming and applying same

• US 20040076831A1
• Filed: 08/06/2003
• Published: 04/22/2004
• Est. Priority Date: 10/02/2002
• Status: Abandoned Application

• Current Assignee: Zephyros, Inc.
• Original Assignee: L&L Products Inc.
• Inventors: Kassa, Abraham, Hable, Christopher
• Application Number:
  US10/635,064
• Publication Number:
  US 20040076831A1
• Time in Patent Office: Days
• US Class Current: 428/413
• 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 7/38 Pressure-sensitive adhesives [PSA]
• CPC Class Codes: Y10T 428/31511 Of epoxy ether

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 coating, a film or a treatment is applied to the base material for providing a substantially non-tacky surface to the synthetic material.

Claims

1. A method of forming a synthetic material, comprising:

providing a base material for of one or more components, the base material being an expandable material that is tacky at a temperature between about 0°

C. and about 80°

C.; and

providing at least one substantially non-tacky surface to the base material to form the synthetic material with the at least one substantially non-tacky surface and at least one tacky surface.

2. A method as in claim 1 wherein the step of providing at least one substantially non-tacky surface includes forming a liquid admixture and applying the liquid admixture to at least one surface of the base material for forming a coating, the coating including the at least one substantially non-tacky surface.

3. A method as in claim 1 wherein the step of providing at least one substantially non-tacky surface includes applying a film to at least one surface of the base material such that the film provides the at least one substantially non-tacky surface.

4. A method as in claim 2 wherein the coating includes one or more correspondence components corresponding to the one or more components of the base material.

5. A method as in claim 4 wherein the one or more correspondence components have a substantially identical monomer and/or oligomer configuration relative to the one or more components of the base material.

6. A method as in claim 5 wherein the one or more correspondence components of the coating include at least one epoxy resin material.

7. A method as in claim 3 wherein the film includes one or more correspondence components corresponding to the one or more components of the base material.

8. A method as in claim 7 wherein the one or more correspondence components have a substantially identical monomer or oligomer configuration relative to the one or more components of the base material.

9. A method as in claim 8 wherein the one or more correspondence components of the coating include at least one epoxy resin material.

10. A method as in claim 1 wherein the step of providing at least one substantially non-tacky surface includes at least partially curing a surface of the base material such that the surface of the base material become the substantially non-tacky surface.

11. A method of forming a synthetic material, comprising:

providing a base material, the base material being tacky at a temperature between about 0°

C. and about 80°

C.;

providing a liquid admixture, the admixture including one or more correspondence components corresponding to one or more components of the base material and the admixture including between about 20% and about 60% by weight solvent or cosolvent wherein the correspondence components are at least partially dissolved in the solvent or cosolvent;

applying the admixture to at least one surface of the base material;

drying the liquid admixture to form a coating upon the base material thereby forming the synthetic material with at least one tacky surface and at least one non-tacky surface, the non-tacky surface being provided by the coating, which is non-tacky at a temperature below about 80°

C.

12. A method as in claim 11 wherein at least a portion of the one or more correspondence components are thermoplastics.

13. A method as in claim 11 wherein at least a portion of the one or more correspondence components are elastomers.

14. A method as in claim 11 wherein one or more correspondence components comprise at least about 60% by weight of fix coating.

15. A method as in claim 11 wherein the solvent or cosolvent is selected from water, toluene, benzene, xylene, alcohol, ethanol, acetone or a combination thereof.

16. A method as in claim 14 wherein the admixture includes between about 5% and about 50% by weight epoxy resin and the epoxy resin has an EEW between about 200 and about 300 and wherein the epoxy resin represents at least a portion of the one or more correspondence components.

17. A method as in claim 11 further comprising contacting the tacky surface with release paper.

18. A method as in claim 11 wherein the one or more correspondence components have a substantially identical monomer or oligomer configuration relative to the one or more components of the base material.

19. A method as in claim 11 wherein the one or more correspondence components include an epoxy resin that is substantially identical to an epoxy resin in the base material.

20. A method of forming a synthetic material and employing the synthetic material for reinforcing or providing acoustical damping to a member of an automotive vehicle, the method comprising:

providing a base material primarily comprised of one or more epoxy components, the base material being tacky at a temperature between about 0°

C. and about 80°

C.;

providing a liquid admixture, the admixture including one or more correspondence components corresponding to the one or more epoxy components of the base material and the admixture including between about 20% and about 60% by weight solvent or cosolvent wherein the correspondence components are at least partially dissolved in the solvent or cosolvent;

applying the admixture to at least one surface of the base material;

drying the liquid admixture to form a coating upon the base material thereby forming the synthetic material with at least one tacky surface and at least one substantially non-tacky surface, the non-tacky surface being provided by the coating;

applying the synthetic material to the member of the automotive vehicle by contacting the substantially non-tacky surface of the synthetic material such that the tacky surface of the synthetic material contacts the member of the automotive vehicle.