Synthetic material and methods of forming and applying same

• US 7,267,738 B2
• Filed: 03/22/2004
• Issued: 09/11/2007
• Est. Priority Date: 08/13/2002
• Status: Active Grant

• Current Assignee: Zephyros, Inc.
• Original Assignee: Zephyros, Inc.
• Inventors: Czaplicki, Michael J., Madaus, Keith
• Primary Examiner(s): SELLERS, ROBERT E
• Application Number:
  US10/806,309
• Publication Number:
  US 20040180206A1
• Time in Patent Office: 1,268 Days
• Field of Search: None
• US Class Current: 156/278
• CPC Class Codes: B05D 7/02 to macromolecular substances, e.g. rubber treatment or coating of shaped articles made of macromolecular substances C08J7/00
• CPC Class Codes: B32B 25/00 Layered products comprising a layer of natural or synthetic rubber fibrous or filamentary layer made of a natural or synthetic rubber B32B5/02; particulate layer made of a natural or synthetic rubber B32B5/16; foamed layer made of a natural or synthetic rubber B32B5/18
• CPC Class Codes: C08J 2207/02 Adhesive
• CPC Class Codes: C08J 5/12 Bonding of a preformed macromolecular material to the same or other solid material such as metal, glass, leather, e.g. using adhesives
• CPC Class Codes: C08J 9/365 Coating
• CPC Class Codes: C09J 2463/00 Presence of epoxy resin
• CPC Class Codes: C09J 7/22 Plastics; Metallised plastics
• CPC Class Codes: C09J 7/35 Heat-activated
• CPC Class Codes: C09J 7/38 Pressure-sensitive adhesives [PSA]
• CPC Class Codes: Y10T 428/2486 with outer strippable or release layer
• CPC Class Codes: Y10T 428/249982 With component specified as adhesive or bonding agent
• CPC Class Codes: Y10T 428/249983 As outermost component
• CPC Class Codes: Y10T 428/249985 Composition of adhesive or bonding component specified
• CPC Class Codes: Y10T 428/31511 Of epoxy ether
• CPC Class Codes: Y10T 428/31663 As siloxane, silicone or silane
• CPC Class Codes: Y10T 428/31725 Of polyamide
• CPC Class Codes: Y10T 428/31736 Next to polyester
• CPC Class Codes: Y10T 428/3175 Next to addition polymer from unsaturated monomer[s]
• CPC Class Codes: Y10T 428/31757 Polymer of monoethylenically unsaturated hydrocarbon
• CPC Class Codes: Y10T 428/31761 Next to aldehyde or ketone condensation product
• CPC Class Codes: Y10T 428/31786 : Of polyester [e.g., alkyd, etc.]
• CPC Class Codes: Y10T 428/31797 : Next to addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31826 : Of natural rubber
• CPC Class Codes: Y10T 428/3183 : Next to second layer of natural rubber
• CPC Class Codes: Y10T 428/31833 : Next to aldehyde or ketone condensation product or addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31855 : Of addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31877 : Phenol-aldehyde
• CPC Class Codes: Y10T 428/31913 : Monoolefin polymer

Abstract

A synthetic material and articles incorporating the same are disclosed. The synthetic material includes a base material, which is at least partially tacky. Preferably, a powder is dispensed upon the base material for providing a substantially non-tacky surface to the synthetic material.

Claims

1. A method of providing reinforcement, acoustical damping, or sealing to a member of an article of manufacture with a synthetic material, the method comprising:

providing a polymeric base material, the base material being tacky at a temperature of about 23°

C.;

providing a polymeric powder, the powder including correspondence components, the powder being substantially non-tacky at a temperature of about 23°

C., the powder exhibiting adhesivity at a temperature greater than 80°

C. wherein the correspondence components include an epoxy resin;

dispensing the powder upon the base material to form the synthetic material with at least one substantially non-tacky surface and at least one tacky surface; and

applying the synthetic material to the member of the article of manufacture.

2. A method as in claim 1 wherein the base material is selected from the group consisting of a thermoplastic-based material, an epoxy-based material and an elastomer based material.

3. A method as in claim 1 wherein the article of manufacture is an automotive vehicle.

4. A method as in claim 3 wherein the member is selected from the group consisting of a frame member and a body member of the automotive vehicle.

5. A method as in claim 1 wherein the correspondence components in the powder have a substantially identical monomer or oligomer configuration to polymeric components in the base material with the exception that the correspondence components in the powder have a greater molecular weight or longer polymeric chain structure than the polymeric components in the base material.

6. A method as in claim 1 wherein the base material includes a blowing agent and is an expandable material.

7. A method as in claim 1 wherein the one or more correspondence components represent at least 30% by weight of the powder.

8. A method of providing reinforcement, acoustical damping, or sealing to a member of an article of manufacture with a synthetic material, the method comprising:

providing a polymeric base material, the base material being tacky at a temperature of about 23°

C. wherein the base material is an expandable material;

providing a polymeric powder, the powder including correspondence components, the powder being substantially non-tacky at a temperature of about 23°

C., the powder exhibiting adhesivity at a temperature greater than 80°

C.;

dispensing the powder upon the base material to form the synthetic material with at least one substantially non-tacky surface and at least one tacky surface; and

applying the synthetic material to the member of the article of manufacture.

9. A method as in claim 8 wherein the step of applying the synthetic material includes contacting the non-tacky surface of the synthetic material such that the tacky surface of the synthetic material is adhered to the member.

10. A method as in claim 9 wherein the contacting of the non-tacky surface is carried out by an individual or a machine.

11. A method as in claim 8 wherein the base material is selected from the group consisting of a thermoplastic-based material, an epoxy-based material and an elastomer based material.

12. A method as in claim 8 wherein the article of manufacture is an automotive vehicle.

13. A method as in claim 12 wherein the member is selected from the group consisting of a frame member and a body member of the automotive vehicle.

14. A method as in claim 8 wherein the one or more correspondence components are substantially identical to one or more components in the base material.

15. A method as in claim 8 wherein the correspondence components in the powder have a substantially identical monomer or oligomer configuration to polymeric components in the base material with the exception that the correspondence components in the powder have a greater molecular weight or longer polymeric chain structure than the polymeric components in the base material.

16. A method as in claim 8 wherein the base material includes a blowing agent and a curing agent.

17. A method as in claim 8 wherein the one or more correspondence components represent at least 30% by weight of the powder.