Structural hot melt material and methods

• US 6,887,914 B2
• Filed: 09/04/2002
• Issued: 05/03/2005
• Est. Priority Date: 09/07/2001
• Status: Expired due to Term

• Current Assignee: Zephyros, Inc.
• Original Assignee: L&L Products Inc.
• Inventors: Kosal, David J., Czaplicki, Michael J., Antrim, Jeanne
• Primary Examiner(s): Foelak, Morton
• Application Number:
  US10/234,902
• Publication Number:
  US 20030069335A1
• Time in Patent Office: 972 Days
• Field of Search: 521/178, 521/135, 521/54, 156/330, 156/547, 156/548, 428/196, 428/234.4, 428/305.5, 428/308.4, 428/322.7
• US Class Current: 521/178
• CPC Class Codes: B62D 27/026 Connections by glue bonding in general F16B11/00; processes C09J5/00
• CPC Class Codes: C08J 2207/02 Adhesive
• CPC Class Codes: C08J 2363/00 Characterised by the use of epoxy resins; Derivatives of epoxy resins
• CPC Class Codes: C08J 9/0066 Use of inorganic compounding ingredients
• 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 63/00 Compositions of epoxy resins; Compositions of derivatives of epoxy resins
• CPC Class Codes: C09J 163/00 Adhesives based on epoxy resins; Adhesives based on derivatives of epoxy resins
• CPC Class Codes: Y10T 156/1722 Means applying fluent adhesive or adhesive activator material between layers
• CPC Class Codes: Y10T 156/1724 At spaced areas
• CPC Class Codes: Y10T 428/2481 including layer of mechanically interengaged strands, strand-portions or strand-like strips
• CPC Class Codes: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/249954 With chemically effective material or specified gas other than air, N, or carbon dioxide in void-containing component
• CPC Class Codes: Y10T 428/249958 Void-containing component is synthetic resin or natural rubbers
• CPC Class Codes: Y10T 428/249999 Differentially filled foam, filled plural layers, or filled layer with coat of filling material

Abstract

The present invention relates to a material, method, and application for reinforcement of structural members, especially joints such as a hem flange joint of an automobile. The method and material of the present invention comprises of combining, in parts by weight: less than about twenty percent (<20%) ethylene copolymer, less than about forty percent (<40%) epoxy, less than about thirty percent (<45%) epoxy-based resin, less than about two percent (<2%) blowing agent and from about one percent (1%) to about five percent (5%) curing agent (and optionally add any of the following components: less than about two percent (<2%) curing agent accelerator, from about twenty-five percent (25%) to fifty-five percent (55%) filler, and less than about one percent (<1%) of coloring agent). The application of the present invention comprises of: (1) providing a structural member having two substrates forming a space to be joined; (2) placing the material of the present invention in proximity of the space to be joined; (3) exposing the material to a heat source causing it to flow, fill, and cure in the defined area or space to be joined.

Claims

1. A method of reinforcing structural members comprising the steps of:

providing a structural member of an automotive vehicle, the structural member having two substrates that form a hem flange, the hem flange forming a space to be joined;

providing a material comprising of in parts by weight;

less than about twenty percent (<

20%) ethylene copolymer, less than about forty percent (<

40%) epoxy, less than about thirty percent (<

45%) epoxy-based resin, less than about two percent (<

2%) blowing agent and from about one percent (1%) to about five percent (5%) curing agent;

placing said material in proximity of said space to be joined;

exposing said material to a heat source that delivers heat energy at a temperature between about 285°

F. and about 400°

F. causing said material to flow, fill, and cure in said space to be joined.

2. The method of claim 1, wherein said material is further comprised at least one component selected from the group consisting of in parts by weight:

less than about two percent (<

2%) curing agent accelerator;

from about twenty-five percent (25%) to fifty-five percent (55%) filler;

less than about one percent (<

1%) coloring agent; and

a combination thereof.

3. The method of claim 1, wherein said heat source exposes said material to a temperature of between about 285°

F. to about 400°

F.

4. The method of claim 2, wherein

said two substrates are cleaned, electrodeposition coated, and exposed to a heat source to form said hem flange joint;

said material is then placed in proximity of said space to be joined of said hem flange joint;

said ethylene polymer is about 3.8 percent ethylene-methyl acrylate copolymer;

said epoxy is about 23.49 percent bisphenol A epoxy;

said epoxy resin is comprised of about 24.24 percent bisphenol A epoxy resin and about 0.26 percent epoxy phenol novoiac resin;

said blowing agent is about 0.12 percent azodicarbonamide;

said curing agent is about 1.55 percent cyanoguanidine;

said curing agent accelerator is about 0.5 percent methylene diphenyl bis;

said filler is about 45.84 percent calcium carbonate;

said coloring agent is about 0.19 percent metal oxide; and

said heat source exposes said material to a temperature of about 340°

F. for about 30 minutes.

5. The method of claim 2, wherein

said structural member having two substrates forming said space to be joined are a hem flange joint of an automobile, wherein said two substrates are cleaned, electrodeposition coated, and exposed to a heat source to form said hem flange joint;

said material is then placed in proximity of said space to be joined of said hem flange joint;

said ethylene polymer is about 3.8 percent ethylene-methyl acrylate copolymer;

said epoxy is about 23.49 percent bisphenol A epoxy;

said epoxy resin is comprised of about 24.24 percent bisphenol A epoxy resin and about 0.26 percent epoxy phenol novoiac resin;

said blowing agent is about 0.12 percent azodicarbonamide;

said curing agent is about 1.55 percent cyanoguanidine;

said curing agent accelerator is about 0.5 percent methylene diphenyl bis;

said filler is about 45.84 percent calcium carbonate;

said coloring agent is about 0.19 percent metal oxide; and

said heat source exposes said material to a temperature of about 340°

F. for about 30 minutes.

6. The method of claim 2, wherein

said hem flange is pre-crimped.

7. The method of claim 2, wherein

said hem flange is crimped.

8. The material of claim 2, wherein said filler is selected from the group consisting of:

calcium carbonate, mica, montmorillinite, aramide pulp, nanoclay, fumed silica, and a combination thereof.

9. The material of claim 1, wherein said epoxy is in a solid state and selected from a group consisting of:

bisphenol A, bisphenol F, novolac, modified urethane, and a combination thereof.

10. A method of reinforcing structural members comprising the steps of:

providing a structural member having two substrates forming a space to be joined, wherein;

i) the two substrates include a first panel and a second panel of an automotive vehicle structure;

ii) the first panel having an arcuate portion forming a cavity that defines at least a portion of the space to be joined and the second panel having an edge received in the cavity;

providing a hot melt thermosettable material comprising an ethylene copolymer, an epoxy-based resin, less than about two percent blowing agent and from about one percent (1%) to about five percent (5%) curing agent;

placing said material in proximity of said space to be joined;

exposing said material to a heat source causing said material to flow, fill, and cure in said space to be joined.

11. The method of claim 10 wherein the two substrates are comprised of a first panel and a second panel.

12. The method claim 11 wherein the first panel and the second panel are part of an automotive vehicle structure selected from a tailgate, a lift gate, or a rear gate.

13. The method of claim 11 wherein the first panel and the second panel are joined to form a hem flange joint.

14. The method of claim 13 wherein providing the hot melt thermosettable material include mixing the material in an extruder.

15. The method of claim 13 wherein the joint is formed without crimping.

16. The method of claim 14 wherein the material contacts the arcuate portion of the first panel and the edge of the second panel.

17. The method of claim 10 wherein the material is thermoset by exposure to the heat source.

18. The method of claim 17 wherein the heat source is an oven employed in e-coat or painting operations applied to the automotive vehicle and the heat source exposes the material to a temperature of between about 285°

F. to about 400°

F.

19. The method of claim 10, wherein the material comprises, in parts by weight, less than about one percent (<

1%) coloring agent wherein said coloring agent is a metal oxide.

20. The method of claim 10, wherein said ethylene polymer is in a solid state and selected from the group consisting of:

ethylene-vinyl acrylate, ethylene-vinyl acetate, ethylene-methyl acrylate, ethylene-butyl acrylate, EMA/GMA, ethylene/α

-olefin, ethylene-ethyl acrylate, and a combination thereof.

21. The method of claim 10, wherein said blowing agent is selected from the group consisting of azodiacarbonamide, p,p-Oxybisbenzene sulfonyl hydrazide, p-Toluene sulfonyl hydrazide, expancel, and a combination thereof.

22. The method of claim 10, wherein said curing agent is selected from the group consisting of cyanoguanidine, dicyanamide, imidazoles, and a combination thereof.

23. A method of reinforcing structural members comprising the steps of:

providing a structural member having two substrates forming a space to be joined wherein;

i) the two substrates include a first panel and a second panel of an automotive vehicle structure selected from a tailgate, a lift gate, or a rear gate;

ii) the first panel and the second panel form a particular hem flange joint having an arcuate portion forming a cavity that defines at least a portion of the space to be joined and the second panel having an edge received in the cavity;

providing a material comprising an ethylene copolymer, an epoxy-based resin, less than about two percent by weight blowing agent and from about one percent (1%) to about five percent (5%) by weight curing agent;

placing said material in proximity of said space to be joined, said material contacting the arcuate portion of the first panel and the edge of the second panel;

exposing said material to a heat source causing said material to flow, fill, and cure in said space to be joined wherein;

i) the material is thermoset by exposure to the heat source; and

ii) the heat source is an oven employed in e-coat or painting operations applied to the automotive vehicle; and

iii) the heat source exposes the material to a temperature of between about 285°

F. to about 400°

F.

24. The method of claim 23, wherein said ethylene polymer is in a solid state and selected from the group consisting of:

ethylene-vinyl acrylate, ethylene-vinyl acetate, ethylene-methyl acrylate, ethylene-butyl acrylate, EMA/GMA, ethylene/α

-olefin, ethylene-ethyl acrylate, and a combination thereof.

25. The method of claim 24, wherein the joint is formed without crimping.