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

• US 7,125,461 B2
• Filed: 05/07/2003
• Issued: 10/24/2006
• Est. Priority Date: 05/07/2003
• Status: Expired due to Fees

• Current Assignee: Zephyros, Inc.
• Original Assignee: L&L Products Inc.
• Inventors: Carlson, David, Czaplicki, Michael J., Hable, Christopher
• Primary Examiner(s): Maki, Steven D.
• Application Number:
  US10/430,993
• Publication Number:
  US 20040221953A1
• Time in Patent Office: 1,266 Days
• Field of Search: 156/79, 156/244.22, 156/293, 156/294, 156/330, 156/283, 156/289, 296/205
• US Class Current: 156/79
• 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) 30% to about 80% by weight epoxy resin;

ii) 5% to about 25% by weight thermoplastic polyether selected from a polyetheramine and a polyamino ether; 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

exposing the activatable material to heat thereby activating the activatable material to bond to surfaces of the structural member;

wherein the thermoplastic polyether has a melt index between about 25 and about 75 per 10 minutes under a load of 2.16 Kg at a temperature of 190°

C.

2. A method as in claim 1 wherein the step of exposing the activatable material occurs in an automotive e-coat or painting operation and the activating of the activatable material includes foaming and curing of the activatable material.

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 activatable material includes a blowing agent.

6. A method as in claim 5 wherein the blowing agent is selected from an azodicarbonamide, a dinitrosopentamethylenetetramine, a 4,4_i-oxy-bis-(benzenesulphonylhydrazide), a trihydrazinotriazine and a N,N_i-dimethyl-N,N_i-dinitrosoterephthalamide.

7. A method as in claim 5 wherein the activatable material includes an ingredient selected from a filler, a clay, a blowing agent accelerator, a curing agent accelerator, and a flexiblizer.

8. 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 and an acetate.

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

10. A method as in claim 1 wherein the activatable material is substantially tack free.

11. A method as in claim 1 wherein the step of applying the activatable material to a surface of a carrier member forms a reinforcement member wherein the carrier member is skeletal and includes a plurality of ribs.

12. 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) between about 40% and about 60% by weight epoxy resin;

ii) between about 5% and about 25% by weight thermoplastic polyether selected from a polyetheramine and a polyamino ether; and

iii) a curing agent;

locating the activatable material within a cavity or upon a surface of a structure of the automotive vehicle; and

exposing the activatable material to heat thereby activating the activatable material to bond to surfaces of the structure;

wherein the thermoplastic polyether has a melt index between about 25 and about 75 per 10 minutes under load of 2.16 Kg at a temperature of 190°

C.

13. A method as in claim 12 wherein the step of exposing the activatable material occurs in an automotive e-coat or painting operation and the activating of the activatable material includes foaming and curing of the activatable material.

14. A method as in claim 12 wherein the activatable material includes a blowing agent.

15. A method as in claim 12 wherein the thermoplastic polyether includes a polymer backbone and includes aromatic ether/amine repeating units in the backbone.

16. A method as in claim 12 further comprising, forming the thermoplastic polyether by reacting a difunctional amine with a glycidyl ether.

17. A method as in claim 12 wherein the thermoplastic polyether is a copolymer of monoethanolamine and diglycidyl ether.

18. A method as in claim 12 wherein the thermoplastic polyether is formed by reacting an amine with an average functionality of 2 or less with a glycidyl ether.

19. A method as in claim 12 wherein the activatable material is substantially tack free.

20. 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) 30% to about 80% by weight epoxy resin;

ii) 5% to about 25% by weight thermoplastic polyether selected from a polyetheramine and a polyamino ether;

iii) a curing agent; and

iv) a blowing agent;

locating the activatable material within a cavity or upon a surface of a structure of the automotive vehicle; and

exposing the activatable material to heat in an automotive e-coat or paint operation thereby activating the activatable material to foam, cure and bond to surfaces of the structure;

wherein the thermoplastic polyether is formed by reacting an amine with an average functionality of 2 or less with a glycidyl ether; and

wherein the thermoplastic polyether has a melt index between about 25 and about 75 per 10 minutes under load of 2.16 Kg at a temperature of about 190°

C.

21. A method as in claim 20 wherein the thermoplastic polyether is a copolymer of monoethanolamine and diglycidyl ether.

22. A method as in claim 21 wherein the blowing agent is selected from an azodicarbonamide, a dinitrosopentamethylenetetramine, a 4,4_i-oxy-bis-(benzenesulphonylhydrazide), a trihydrazinotriazine and a N,N_i-dimethyl-N,N_i-dinitrosoterephthalamide.

23. A method as in claim 22 wherein the activatable material includes an ingredient selected from a filler, a clay, a blowing agent accelerator, a curing agent accelerator, and a flexiblizer.

24. 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 and an acetate.

25. A method as in claim 24 wherein locating of the activatable material within a cavity or upon a surface of a structure of the automotive vehicle includes applying the activatable material to a carrier and inserting the carrier and the activatable material into the cavity of the structure of the automotive vehicle.

26. A method as in claim 24 wherein locating the activatable material includes extruding the activatable material onto the surface of the carrier member.

27. A method as in claim 26 wherein the activatable material is substantially tack free.