Expandable compositions and methods of making and using the compositions

• US 20050096401A1
• Filed: 10/13/2004
• Published: 05/05/2005
• Est. Priority Date: 10/26/1999
• Status: Active Grant

• Current Assignee: Henkel IP & Holding GmbH (Henkel AG & Co KGaA)
• Original Assignee: Orbseal LLC (BASF SE)
• Inventors: Tkacz, Peter, Duffin, Gary Raymond, Taylor, Donald W., Lupini, Michael Allen
• Granted Patent: US 7,247,657 B2
• Time in Patent Office: Days
• US Class Current: 521/50
• CPC Class Codes: B29C 44/184 and inserting the bags into preformed cavities
• CPC Class Codes: C08L 2203/14 used for foams
• CPC Class Codes: C08L 23/08 Copolymers of ethene C08L23/16 takes precedence
• CPC Class Codes: C08L 23/0869 Acids or derivatives thereof
• CPC Class Codes: C08L 2666/02 Organic macromolecular compounds, natural resins, waxes or and bituminous materials
• CPC Class Codes: C08L 2666/04 Macromolecular compounds according to groups C08L7/00 - C08L49/00, or C08L55/00 - C08L57/00; Derivatives thereof
• CPC Class Codes: C08L 51/06 grafted on to homopolymers or copolymers of aliphatic hydrocarbons containing only one carbon-to-carbon double bond
• CPC Class Codes: C09K 2003/1037 Intumescent materials
• CPC Class Codes: C09K 2200/06 Macromolecular organic compounds, e.g. prepolymers
• CPC Class Codes: C09K 2200/062 Polyethylene
• CPC Class Codes: C09K 2200/0622 Polyvinylalcohols, polyvinylacetates
• CPC Class Codes: C09K 3/10 Materials in mouldable or extrudable form for sealing or packing joints or covers filling pastes C09D5/34
• CPC Class Codes: Y10T 428/1383 Vapor or gas barrier, polymer derived from vinyl chloride or vinylidene chloride, or polymer containing a vinyl alcohol unit is sandwiched between layers [continuous layer]
• CPC Class Codes: Y10T 428/24273 including aperture

Abstract

A novel expandable composition and method for using the same are disclosed. The disclosed method relates to using the composition, for example, as an automotive cavity sealant. The inventive composition normally is a combination of at least one base polymer, at least one expansion or blowing agents, at least one hydrocarbon resin, at least one curing agent or catalyst and optionally at least one additives such as a supplemental polymer, colorant, tackifier, processing oil, among others.

Claims

1-14. -14. (canceled).

15. A composition comprising a maleic anhydride-modified copolymer of ethylene and vinyl acetate, at least one expansion agent, at least one hydrocarbon resin, and at least one sulfur containing curing agent.

16. The composition of claim 15 wherein at least one expansion agent is a hydrazide.

17. The composition of claim 15 wherein at least one expansion agent is selected from the group consisting of p,p′

-oxybis(benzenesulfonyl hydrazide) and diphenylazide-4,4′

-disulphohydrazides.

18. The composition of claim 15 wherein at least one hydrocarbon resin is selected from the group consisting of rosin esters, polyterpenes and C5 to C9 hydrocarbon and aromatically modified hydrocarbon resins.

19. The composition of claim 15 wherein at least one sulfur containing curing agent is tetramethylthiuram disulfide.

20. The composition of claim 15 additionally comprising at least one processing oil.

21. The composition of claim 15 additionally comprising at least one supplemental polymer selected from the group consisting of ethylene acrylic acid copolymers, polybutadienes, ethylene vinyl acetate polymers, and ethylene propylene diene monomer polymers.

22. The composition of claim 15 additionally comprising at least one filler.

23. The composition of claim 15 wherein the maleic anhydride-modified copolymer of ethylene and vinyl acetate comprises from about 50 to about 90 weight percent of the composition.

24. The composition of claim 15 wherein the at least one hydrocarbon resin comprises from about 1 to about 15 weight percent of the composition.

25. The composition of claim 15 wherein the at least one expansion agent comprises from about 1 to about 15 weight percent of the composition.

26. The composition of claim 15 additionally comprising at least one urea or modified urea.

27. The composition of claim 15 comprising both p,p′

-oxybis(benzenesulfonyl hydrazide) and a diphenylazide4,4′

-disulphohydrazide.

28. The composition of claim 15 comprising about 55 to about 84 weight percent of the maleic anhydrid-modified copolymer of ethylene and vinyl acetate, about 1 to about 15 weight percent of the at least one expansion agent, said at least one expansion agent being selected from the group consisting of p,p′

-oxybis(benzenesulfonyl hydrazide) and diphenylazide-4,4′

-disulphohydrazides, about 1 to about 15 weight percent of the at least one hydrocarbon resin, and up to about 5 weight percent of tetramethylthiuram disulfide.

29. The composition of claim 28 additionally comprising from about 5 to about 10 weight percent of at least one supplemental polymer selected from the group consisting of ethylene acrylic acid copolymers and polybutadienes.

30. The composition of claim 28 additionally comprising at least one urea or modified urea.

31. The composition of claim 28 additionally comprising at least one filler.

32. The composition of claim 28 wherein at least one hydrocarbon resin is selected from the group consisting of rosin esters, polyterpenes and C5 to C9 hydrocarbon and aromatically modified hydrocarbon resins.

33. The composition of claim 28 additionally comprising at least one peroxide.

34. The composition of claim 28 additionally comprising at least one processing oil.

35. The composition of claim 28 comprising both p,p′

-oxybis(benzenesulfonyl hydrazide) and a diphenylazide 4,4′

-disulphohydrazide.

36. The composition of claim 28 wherein at least one expansion agent is pretreated with a naphthenic binder.

37. The composition of claim 15, wherein said composition has been injection molded.

38. The composition of claim 15, wherein said composition has been injection molded to form a self-retaining sealant.