Melt-flowable materials and method of sealing surfaces

• US 6,030,701 A
• Filed: 09/20/1996
• Issued: 02/29/2000
• Est. Priority Date: 04/15/1993
• Status: Expired due to Term

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Johnson, Michael A., Meyer, Scott R., George, Clayton A., Willett, Peggy S.
• Primary Examiner(s): ZIRKER, DANIEL R
• Application Number:
  US08/716,919
• Time in Patent Office: 1,257 Days
• Field of Search: 428/343, 428/354, 428/355 EP, 428/355 AC, 428/480, 428/458
• US Class Current: 428/343
• CPC Class Codes: B29L 2031/26 Sealing devices, e.g. packaging for pistons or pipe joints
• CPC Class Codes: B32B 2250/24 All layers being polymeric
• CPC Class Codes: B32B 2323/04 Polyethylene
• CPC Class Codes: B32B 2363/00 Epoxy resins
• CPC Class Codes: B32B 2367/00 Polyesters, e.g. PET, i.e. polyethylene terephthalate
• CPC Class Codes: B32B 27/04 as impregnant, bonding, or embedding substance not used
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/36 comprising polyesters
• CPC Class Codes: B32B 27/38 comprising epoxy resins
• CPC Class Codes: B32B 7/04 Interconnection of layers
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B60J 10/34 using adhesives
• CPC Class Codes: B60R 13/04 External Ornamental or guard strips; Ornamental inscriptive devices thereon fastening strips or bars to sheets or plates by means of clips F16B5/12
• CPC Class Codes: B60R 13/06 Sealing strips sealing arrangements for vehicle windows, windscreens, non-fixed roofs, doors, or similar devices B60J10/00
• CPC Class Codes: C08G 59/68 characterised by the catalysts used
• CPC Class Codes: C08J 5/121 by heating
• CPC Class Codes: C08L 2666/18 Polyesters or polycarbonates according to C08L67/00 - C08L69/00; Derivatives thereof
• CPC Class Codes: C08L 2666/22 Macromolecular compounds not provided for in C08L2666/16 - C08L2666/20
• CPC Class Codes: C09J 163/00 : Adhesives based on epoxy resins; Adhesives based on derivatives of epoxy resins
• CPC Class Codes: C09J 167/02 : Polyesters derived from dicarboxylic acids and dihydroxy compounds C09J167/06 takes precedence
• CPC Class Codes: C09J 2301/1242 : the opposite adhesive layers being different
• CPC Class Codes: C09J 2301/162 : the carrier being a laminate constituted by plastic layers only
• CPC Class Codes: C09J 2400/226 : in the substrate
• CPC Class Codes: C09J 2423/006 : in the substrate
• CPC Class Codes: C09J 2463/00 : Presence of epoxy resin
• CPC Class Codes: C09J 2463/006 : in the substrate
• CPC Class Codes: C09J 2467/006 : in the substrate
• CPC Class Codes: C09J 5/06 : involving heating of the applied adhesive
• CPC Class Codes: C09J 7/10 : without carriers
• CPC Class Codes: C09J 7/20 : characterised by their carriers
• CPC Class Codes: C09J 7/22 : Plastics; Metallised plastics
• CPC Class Codes: C09J 7/29 : Laminated material metallised plastics C09J7/22
• CPC Class Codes: C09J 7/35 : Heat-activated
• CPC Class Codes: C09J 7/38 : Pressure-sensitive adhesives [PSA]
• CPC Class Codes: H05K 3/386 : by the use of an organic polymeric bonding layer, e.g. adhesive
• CPC Class Codes: Y10T 428/249978 : Voids specified as micro
• CPC Class Codes: Y10T 428/24998 : Composite has more than two layers
• CPC Class Codes: Y10T 428/28 : Web or sheet containing structurally defined element or component and having an adhesive outermost layer
• CPC Class Codes: Y10T 428/2826 : Synthetic resin or polymer
• CPC Class Codes: Y10T 428/287 : including epoxy group or epoxy polymer
• CPC Class Codes: Y10T 428/2891 : including addition polymer from alpha-beta unsaturated carboxylic acid [e.g., acrylic acid, methacrylic acid, etc.] Or derivative thereof
• CPC Class Codes: Y10T 428/31786 : Of polyester [e.g., alkyd, etc.]

Abstract

The invention provides a method for imparting topographical or protective features to a substrate by contacting a sheet material comprising a thermosettable layer with a substrate and heating the sheet material to an elevated temperature.

Claims

1. A article adapted for placement on the surface of a substrate comprising:

(a) a melt-flowable composition that flows and substantially covers a desired area of the surface of the substrate when said article is heated to a temperature sufficient to cause said melt-flowable composition to flow; and

(b) a dimensionally stable film for controlling the melt-flow behavior of said melt-flowable composition to substantially confine said melt-flowable composition to the desired area of the surface of the substrate when said article is heated to a temperature sufficient to cause said melt-flowable composition to flow,

said dimensionally stable film having a preselected surface topography which is substantially retained when said article is heated to a temperature sufficient to cause said melt-flowable composition to flow,

said dimensionally stable film having sufficient integrity such that;

(i) it does not melt and flow when heated to temperatures sufficient to cause said melt-flowable composition to melt and flow.

2. An article according to claim 1 wherein said melt-flowable composition comprises a thermoplastic composition.

3. An article according to claim 1 wherein said melt-flowable composition comprises a thermosetting composition.

4. An article according to claim 1 wherein said melt-flowable composition comprises a semi-crystalline, thermosetting composition comprising an epoxy-polyester blend.

5. An article according to claim 1 wherein said melt-flowable composition comprises a thermosetting composition comprising an epoxy-acrylate blend.

6. An article according to claim 1 wherein said melt-flowable composition comprises a first melt-flowable layer and a second melt-flowable layer in which said first melt-flowable layer flows to a greater extent than said second melt-flowable layer when said article is heated to a temperature sufficient to cause said melt-flowable composition to flow, said first melt-flowable layer being adapted for placement on the surface of the substrate.

7. An article according to claim 1 wherein said melt-flowable composition comprises a first melt-flowable layer and a second melt-flowable layer adapted for placement on the surface of the substrate in which said second melt-flowable layer flows to a greater extent than said first melt-flowable layer when said article is heated to a temperature sufficient to cause said melt-flowable composition to flow to substantially encapsulate said first melt-flowable layer.

8. An article according to claim 1 wherein said melt-flowable composition comprises a thermally activated expansion agent.

9. An article according to claim 1 wherein said melt-flowable composition comprises a photo-curable, melt-flowable layer and a thermally curable, melt-flowable layer.

10. An article according to claim 1 wherein said article is adapted for placement on the surface of a metal joint of a vehicle.

11. An article according to claim 1 wherein said article is adapted for placement on the surface of a roof ditch of a vehicle.

12. An article according to claim 1 wherein said dimensionally stable film comprises an ultra-high molecular weight polyolefin.

13. An article according to claim 1 wherein said dimensionally stable film comprises an ultra-high molecular weight microporous polyolefin.

14. An article according to claim 1 wherein said dimensionally stable film comprises an oriented polyester.

15. An article according to claim 1 wherein said dimensionally stable film comprises oriented polyethylene terephthalate.

16. An article according to claim 1 wherein said dimensionally stable film comprises a B-staged thermosetting composition.

17. An article according to claim 16 wherein said B-staged thermosetting composition comprises a B-staged epoxy-polyester blend.

18. An article according to claim 1 wherein said dimensionally stable film comprises a substantially smooth surface topography.

19. An article according to claim 1 wherein said dimensionally stable film comprises a substantially smooth, paint-receptive surface that remains substantially smooth after said article has been placed on the surface of a substrate, heated to a temperature sufficient to cause said melt-flowable composition to flow, and then cooled.

20. An article according to claim 19 wherein said dimensionally stable film comprises a substantially smooth, paint-receptive surface comprising a thermosetting epoxy-polyester blend.

21. An article according to claim 19 wherein said dimensionally stable film comprises an oriented polyester film provided on one surface with a thermosetting epoxy-polyester blend.

22. An article according to claim 19 wherein said dimensionally stable film comprises a substantially smooth, paint-receptive surface comprising an ethylene-vinyl alcohol film.

23. An article according to claim 1 wherein said dimensionally stable film exhibits a downweb and crossweb shrinkage of less than about 5% when heated at a temperature sufficient to cause said melt-flowable composition to flow.

24. An article according to claim 1 wherein said dimensionally stable film exhibits a downweb and crossweb shrinkage of less than about 2% when heated to a temperature sufficient to cause said melt-flowable composition to flow.

25. An article according to claim 1 wherein said dimensionally stable film exhibits a downweb shrinkage of less than about 1% and a crossweb shrinkage of less than about 0.5% when heated to a temperature sufficient to cause said melt-flowable composition to flow.

26. An article according to claim 1 wherein said melt-flowable composition comprises a plurality of melt-flowable layers in which the melt-flowable properties of the individual layers are tailored such that said layers cooperate with each other to achieve the desired coverage of said surfaces.