Paintable material

• US 6,682,818 B2
• Filed: 08/24/2001
• Issued: 01/27/2004
• Est. Priority Date: 08/24/2001
• Status: Expired due to Fees

• Current Assignee: Zephyros, Inc.
• Original Assignee: L&L Products Inc.
• Inventors: Bradley, Renee, Czaplicki, Michael J., Bradley, Jeff
• Primary Examiner(s): Dawson, Robert
• Assistant Examiner(s): Keehan, Christopher M.
• Application Number:
  US09/939,245
• Publication Number:
  US 20030049453A1
• Time in Patent Office: 886 Days
• Field of Search: 428/413, 428/343, 428/355.EP, 428/355.AC
• US Class Current: 428/413
• CPC Class Codes: C08L 2666/02 Organic macromolecular compounds, natural resins, waxes or and bituminous materials
• CPC Class Codes: C08L 53/02 of vinyl-aromatic monomers and conjugated dienes
• CPC Class Codes: C09J 153/02 Vinyl aromatic monomers and conjugated dienes
• CPC Class Codes: C09J 163/00 Adhesives based on epoxy resins; Adhesives based on derivatives of epoxy resins
• 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 428/287 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 428/31511 Of epoxy ether
• CPC Class Codes: Y10T 428/31678 Of metal
• CPC Class Codes: Y10T 428/31692 Next to addition polymer from unsaturated monomers

Abstract

A sealant material and articles incorporating the same. The sealant material includes up to about 80% of an epoxy resin; up to about 40% of an epoxy/elastomer hybrid; up to about 40% of a rheology modifier; up to about 5% of a blowing agent; up to about 7% of a curing agent; and about 40 to about 60% of a filler.

Claims

1. An article of manufacture, comprising:

a) a first panel;

b) a second panel adjoining said first panel;

c) a sealant that is free of a photoinitiator over said first panel and said second panel;

said sealant material being at least Partially cured prior to coating;

said sealant material consisting essentially of;

i. an effective amount of an epoxy resin, the effective amount of epoxy resin being up to about 80% by weight of the sealant material,

ii. an-effective amount of an epoxy/elastomer hybrid, the effective amount of epoxy/elastomer hybrid being up to about 40% by weight of the sealant material, the epoxy/elastomer hybrid having about 1;

3 to 3;

1 parts of epoxy to elastomer;

iii. an effective amount of a rheology modifier, the effective amount of rheology modifier being up to about 40% by weight of the sealant material;

iv. an effective amount of a blowing agent, the effective amount of blowing agent being up to about 5% by weight of the sealant material;

v. an effective amount of a curing agent and an accelerator, the effective amount of curing agent and accelerator being up to about 7% by weight of the sealant material; and

vi. a filler;

d) a layer of primer over said sealant; and

e) a layer of paint over said primer.

4. The article of claim 1, wherein said sealant is substantially free of ethylene vinyl acetate.

5. The article of claim 1, wherein said sealant has been partially cured.

10. The article of claim 1, wherein said curing agent is an amidoamine.

11. The article of claim 1, wherein said curing agent is an a polyamide.

12. The article of claim 1, wherein said curing agent is a cycloaliphatic amines.

13. The article of claim 1, wherein said curing agent is selected from an aliphatic or aromatic amine or their respective adducts.

2. An article of manufacture, comprising:

a) a first panel and a second panel of an automotive vehicle;

b) a sealant material over said first panel and said second panel and being employed by itself and without any separately fabricated support substrate;

the sealant material being at least partially cured prior to coating;

said sealant material including

i. an effective amount of an epoxy resin, the effective amount of epoxy resin being up to about 80% by weight of the sealant material,

ii. an effective amount of an epoxy/elastomer hybrid, the effective amount of epoxy/elastomer hybrid being up to about 40% by weight of the sealant material, the epoxy/elastomer hybrid having about 1;

3 to 3;

1 parts of epoxy to elastomer;

iii. an effective amount of an rheology modifier other than an ethylene vinyl acetate and including an acrylic, the effective amount of rheology modifier being up to about 40% by weight of the sealant material;

iv. an effective amount of a blowing agent, the effective amount of blowing agent being up to about 5% by weight of the sealant material;

v. an effective amount of a curing agent, the effective amount of curing agent being up to about 7% by weight of the sealant material, the curing agent including an amine; and

vi. about 40 to about 60% of a mineral filler, wherein said sealant is substantially free of a photoinitiator.

6. The article of claim 2, wherein said epoxy resin is present in an amount of about 10 to about 50% by weight, and said epoxy/elastomer hybrid is present in an amount of about 10 to about 30% by weight and has about 1:

3 to 3;

1 parts of epoxy to elastomer.

7. The article of claim 6, wherein said filler is a mineral filler.

16. The article of claim 6, wherein the epoxy/elastomer hybrid includes a blend of an epoxy and a thermoplastic elastomer.

17. The article of claim 6, wherein the epoxy/elastomer hybrid includes a blend of an epoxy and a thermosetting elastomer.

18. The article of claim 6, wherein the epoxy/elastomer hybrid includes a blend of an epoxy and a mixture of a thermosetting elastomer and a thermoplastic elastomer.

19. The article of claim 6, wherein the epoxy/elastomer hybrid includes a copolymer of an epoxy and a thermoplastic elastomer, a thermosetting elastomer or a mixture thereof.

20. The article of claim 6, further comprising an accelerator.

3. An article of manufacture, comprising:

a) a first metal automotive vehicle panel selected from aluminum, steel or reinforced plastic;

b) a second automotive vehicle panel selected from aluminum, steel or reinforced plastic adjoining said first panel;

c) a sealant that is substantially free of a photoinitiator;

over said first panel and said second panel;

said sealant material being at least partially cured prior to coating and consisting essentially of;

1. about 10 to about 50 parts by weight of an epoxy resin;

2. about 10 to about 30 parts by weight of an epoxy/elastomer hybrid having about 1;

3 to 3;

1 parts of epoxy to elastomer;

3. an effective amount of a rheology modifier including an acrylic, the effect amount of rheology modifier being up about 10 parts by weight of the sealant material;

4. an effective amount of a blowing agent, the effective amount of blowing agent up to about 5 parts by weight of the sealant material;

5. an effective amount of a curing agent, the effective curing agent being up to 7 parts by weight of the sealant material, the curing agent including an amine; and

6. about 40 to about 60 parts by weight of a mineral filler;

d) a layer of primer over said sealant; and

e) a layer of paint over said primer.

8. The article of claim 3, wherein said sealant is substantially free of ethylene vinyl acetate.

9. The article of claim 3, wherein said sealant is self leveling at elevated temperatures for providing a smooth paintable surface.

14. The article of claim 3, wherein the partial cure is effected using an acid cure for inducing homopolymerization on or within the material.

15. The article of claim 3, wherein the partial cure is effected using a liquid for effectuating the initiation of a condensation reaction.