Activatable material for sealing, baffling or reinforcing and method of forming same

• US 20040221953A1
• Filed: 05/07/2003
• Published: 11/11/2004
• Est. Priority Date: 05/07/2003
• Status: Active Grant

• Current Assignee: Zephyros, Inc.
• Original Assignee: L&L Products Inc.
• Inventors: Carlson, David, Czaplicki, Michael J., Hable, Christopher
• Granted Patent: US 7,125,461 B2
• Time in Patent Office: Days
• US Class Current: 156/293
• CPC Class Codes: B62D 29/002 a foamable synthetic material or metal being added in situ shaping of substances in a plastic state by foaming, in general B29C44/00
• CPC Class Codes: C08G 2650/56 Polyhydroxyethers, e.g. phenoxy resins
• CPC Class Codes: C08J 2363/00 Characterised by the use of epoxy resins; Derivatives of epoxy resins
• CPC Class Codes: C08J 9/10 developing nitrogen , the blowing agent being a compound containing a nitrogen-to-nitrogen bond
• CPC Class Codes: C08L 2666/02 Organic macromolecular compounds, natural resins, waxes or and bituminous materials
• CPC Class Codes: C08L 2666/22 Macromolecular compounds not provided for in C08L2666/16 - C08L2666/20
• CPC Class Codes: C08L 63/00 Compositions of epoxy resins; Compositions of derivatives of epoxy resins
• CPC Class Codes: C08L 71/00 Compositions of polyethers obtained by reactions forming an ether link in the main chain of polyacetals C08L59/00; of epoxy resins C08L63/00; of polythioether-ethers C08L81/02; of polyether-sulfones C08L81/06; Compositions of derivatives of such polymers
• CPC Class Codes: C08L 71/02 Polyalkylene oxides
• CPC Class Codes: C09D 163/00 Coating compositions based on epoxy resins; Coating compositions based on derivatives of epoxy resins
• CPC Class Codes: C09D 171/00 Coating compositions based on polyethers obtained by reactions forming an ether link in the main chain based on polyacetals C09D159/00; based on epoxy resins C09D163/00; based on polythioether-ethers C09D181/02; based on polyethersulfones C09D181/06; Coating compositions based on derivatives of such polymers
• CPC Class Codes: C09D 171/02 Polyalkylene oxides
• CPC Class Codes: C09J 163/00 Adhesives based on epoxy resins; Adhesives based on derivatives of epoxy resins
• CPC Class Codes: C09J 171/00 Adhesives based on polyethers obtained by reactions forming an ether link in the main chain based on polyacetals C09J159/00; based on epoxy resins C09J163/00; based on polythioether-ethers C09J181/02; based on polyethersulfones C09J181/06; Adhesives based on derivatives of such polymers
• CPC Class Codes: C09J 171/02 Polyalkylene oxides

Abstract

An activatable material and articles incorporating the same is disclosed. The activatable material includes at least three of an epoxy resin; a thermoplastic polyether; a blowing agent; a curing agent; and a filler. The activatable material is preferably used for sealing, baffling or reinforcing an article of manufacture such as an automotive vehicle.

Claims

1. A method of sealing, baffling or reinforcing a portion of an automotive vehicle, the method comprising:

providing an activatable material, the activatable material including;

i) an epoxy resin;

ii) a thermoplastic polyether; and

iii) a curing agent;

applying the activatable material to a surface of a carrier member;

inserting the carrier member with the activatable material disposed thereon into a cavity that is at least partially defined by a structural member of the automotive vehicle; and

activating the activatable material to bond the activatable material to surfaces of the structural member.

2. A method as in claim 1 wherein the thermoplastic polyether is selected from a polyetheramine and a polyamino ether.

3. A method as in claim 1 wherein the thermoplastic polyether includes a polymer backbone and includes aromatic ether/amine repeating units in the backbone.

4. A method as in claim 1 further comprising, forming the thermoplastic polyether by reacting a difunctional amine with a glycidyl ether.

5. A method as in claim 1 wherein the thermoplastic polyether is between about 3% and about 60% by weight of the activatable material.

6. A method as in claim 1 wherein the activatable material includes a blowing agent.

7. A method as in claim 6 wherein the blowing agent is selected from an azodicarbonamide, a dinitrosopentamethylenetetramine, a 4,4_i-oxy-bis-(benzenesulphonylhydrazide), a trihydrazinotriazine or a N, N_i-dimethyl-N,N_i-dinitrosoterephthalamide.

8. A method as in claim 6 wherein the activatable material includes an ingredient selected from a filler, a clay, a curing agent, a blowing agent accelerator, a curing agent accelerator, or a flexiblizer.

9. A method as in claim 1 wherein the activatable material further includes a polymeric material selected from an elastomer-containing adduct, a halogenated polymer, a polycarbonate, a polyketone, a urethane, a polyester, a silane, a sulfone, an allyl, an olefin, a styrene, an acrylate, a silicone, a phenolic, a polyphenylene oxide, a terphthalate or an acetate.

10. A method as in claim 1 wherein applying the activatable material includes extruding the activatable material onto the surface of the carrier member.

11. A method of sealing, baffling or reinforcing a portion of an automotive vehicle, the method comprising:

providing an activatable material, the activatable material including;

i) an epoxy resin;

ii) a thermoplastic polyether; and

iii) a curing agent;

applying the activatable material to a surface of a component of the automotive vehicle; and

activating the activatable material to bond the activatable material to the surface of the component.

12. A method as in claim 11 wherein the thermoplastic polyether is selected from a polyetheramine and a polyamino ether.

13. A method as in claim 11 wherein the thermoplastic polyether includes a polymer backbone and includes aromatic ether/amine repeating units in the backbone.

14. A method as in claim 11 further comprising, forming the thermoplastic polyether by reacting a difunctional amine with a glycidyl ether.

15. A method as in claim 11 wherein the thermoplastic polyether is between about 3% and about 60% by weight of the activatable material.

16. A method as in claim 11 wherein the activatable material includes a blowing agent.

17. A method as in claim 16 wherein the blowing agent is selected from an azodicarbonamide, a dinitrosopentamethylenetetramine, a 4,4_i-oxy-bis-(benzenesulphonylhydrazide), a trihydrazinotriazine or a N, N_i-dimethyl-N,N_i-dinitrosoterephthalamide.

18. A method as in claim 16 wherein the activatable material includes an ingredient selected from a filler, a clay, a curing agent, a blowing agent accelerator, a curing agent accelerator, or a flexiblizer.

19. A method as in claim 11 wherein the activatable material further includes a polymeric material selected from an elastomer-containing adduct, a halogenated polymer, a polycarbonate, a polyketone, a urethane, a polyester, a silane, a sulfone, an allyl, an olefin, a styrene, an acrylate, a silicone, a phenolic, a polyphenylene oxide, a terphthalate or an acetate.

20. A method as in claim 11 wherein applying the activatable material includes extruding the activatable material onto the surface of the component.

21. A method as in claim 11 wherein the step of providing the activatable material includes providing masses of the activatable material packaged together in contact with each other.

22. A method as in claim 21 wherein the step of applying the activatable material to a surface of a component of the automotive vehicle includes separating at least one mass of the activatable material from the masses of the activatable material.

23. A method of sealing, baffling or reinforcing a portion of an automotive vehicle, the method comprising:

providing an activatable material, the activatable material including;

i) an epoxy resin;

ii) a thermoplastic polyether; and

iii) a curing agent;

forming the activatable into a powder, the powder being substantially non-tacky;

providing a tacky adhesive material;

applying the powder to the tacky adhesive material for forming a synthetic material having a tacky surface and a coated non-tacky surface;

contacting the coated non-tacky surface so as to bring the tacky surface into contact with a component of the automotive vehicle; and

activating the activatable material to bond the activatable material to the component of the automotive vehicle.

24. A method as in claim 23 wherein the thermoplastic polyether is selected from a polyetheramine and a polyamino ether.

25. A method as in claim 23 wherein the thermoplastic polyether includes a polymer backbone and includes aromatic ether/amine repeating units in the backbone.

26. A method as in claim 23 further comprising, forming the thermoplastic polyether by reacting a difunctional amine with a glycidyl ether.

27. A method as in claim 23 wherein the thermoplastic polyether is between about 3% and about 60% by weight of the activatable material.

28. A method as in claim 23 wherein the activatable material includes a blowing agent.

29. A method as in claim 28 wherein the blowing agent is selected from an azodicarbonamide, a dinitrosopentamethylenetetramine, a 4,4_i-oxy-bis-(benzenesulphonylhydrazide), a trihydrazinotriazine or a N, N_i-dimethyl-N,N_i-dinitrosoterephthalamide.

30. A method as in claim 28 wherein the activatable material includes an ingredient selected from a filler, a clay, a curing agent, a blowing agent accelerator, a curing agent accelerator, or a flexiblizer.

31. A method as in claim 23 wherein the activatable material further includes a polymeric material selected from an elastomer-containing adduct, a halogenated polymer, a polycarbonate, a polyketone, a urethane, a polyester, a silane, a sulfone, an allyl, an olefin, a styrene, an acrylate, a silicone, a phenolic, a polyphenylene oxide, a terphthalate or an acetate.

32. A method as in claim 23 wherein applying the activatable material includes extruding the activatable material onto the surface of the carrier member.