Method of sealing an interface

• US 7,521,093 B2
• Filed: 07/18/2005
• Issued: 04/21/2009
• Est. Priority Date: 07/21/2004
• Status: Active Grant

• Current Assignee: Zephyros, Inc.
• Original Assignee: Zephyros, Inc.
• Inventors: Carlson, David, Ferng, William B., Jensen, Blair, Knepper, Craig, Hable, Christopher, Chmielewski, Craig, Kassa, Abraham, Harthcock, Matthew, Finerman, Terry
• Primary Examiner(s): Fletcher, III; William Phillip
• Application Number:
  US11/188,010
• Publication Number:
  US 20060020076A1
• Time in Patent Office: 1,373 Days
• Field of Search: 427/301, 427/375, 427/407.1, 427/409, 427/410
• US Class Current: 427/375
• CPC Class Codes: B05D 3/108 Curing
• CPC Class Codes: C08G 59/18 Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
• CPC Class Codes: C09D 5/34 Filling pastes materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12
• CPC Class Codes: C09K 2200/0647 Polyepoxides
• CPC Class Codes: C09K 3/10 Materials in mouldable or extrudable form for sealing or packing joints or covers filling pastes C09D5/34

Abstract

A method of sealing an interface, the method comprising: providing a sealant material, locating the sealant material adjacent to the interface, exposing the sealant material to an elevated temperature such that the sealant material flows adjacent the interface, and curing the sealant material to seal the interface.

Claims

1. A method of sealing an interface, the method comprising:

providing a sealant material;

locating the sealant material adjacent to the interface;

exposing the sealant material to an elevated temperature such that the sealant material flows adjacent the interface; and

curing the sealant material to seal the interface;

wherein the interface is created by two panels of an automotive vehicle; and

wherein prior to exposing the sealant material to an elevated temperature, coating a surface of the sealant material with a curing agent or curing agent accelerator for hardening the surface of the sealant material.

2. A method as in claim 1 wherein the sealant material includes:

i. an epoxy resin;

ii. an epoxy/elastomer adduct;

iii. a rheology modifier selected from an olefinic, a styrenic, an acrylic, an unsaturated carboxylic acid or an ester of a carboxylic ester;

iv. a curing agent; and

v. a filler.

3. A method as in claim 1 wherein the exposing step and the curing step are at least partially simultaneous and the sealant material is thermoset upon curing.

4. A method as in claim 1 wherein the sealant material includes an ingredient such that the sealant material, during the exposing step, maintains a surface energy that is no more than 25% greater or less than the surface energy of the panels at the interface.

5. A method as in claim 1 wherein the sealant material is configured to, during the exposing step, maintain a viscosity of below about 5000 centipoise for between about 15seconds and about 5minutes, the sealant material includes an encapsulated curing agent or curing agent accelerator, or a combination of both.

6. A method as in claim 1 wherein the sealant material is located upon a surface of one of the panels, but spaced away from the interface, and, during the exposing step flows to cover the interface.

7. A method as in claim 1 wherein:

(i) the sealant material has a U-shaped cross-section;

(ii) the sealant material, upon placement adjacent the interface, has a cantilevered portion;

(iii) the sealant material has braided configuration;

or

(iv) any combination thereof.

8. A method as in claim 1 wherein:

(i) the sealant material is attached to a trim piece during locating of the sealant material adjacent the interface;

(ii) the sealant material includes magnetic particles for assisting in locating the sealant material adjacent the interface;

or

(iii) a combination of both.

9. A method of sealing an interface, the method comprising:

providing a sealant material;

locating the sealant material adjacent to the interface;

exposing the sealant material to an elevated temperature such that the sealant material flows adjacent the interface; and

curing the sealant material to seal the interface;

wherein the interface is created by two panels of an automotive vehicle; and

wherein the step of providing the sealant material includes coextruding a layer of first material with a mass of the sealant material and wherein the layer of first material is configured to maintain a higher viscosity during the exposing step or the layer of first material is configured to cure faster than the sealant material during the curing step.

10. A method as in claim 9 wherein the sealant material includes:

(i) an epoxy resin;

(ii) an epoxy/elastomer adduct;

(iii) a rheology modifier selected from an olefinic, a styrenic, an acrylic, an unsaturated carboxylic acid or an ester of a carboxylic ester;

(iv) a curing agent; and

(v) a filler.

11. A method as in claim 9 wherein the exposing step and the curing step are at least partially simultaneous and the sealant material is thermoset upon curing.

12. A method as in claim 9 wherein the sealant material includes an ingredient such that the sealant material, during the exposing step, maintains a surface energy that is no more than 25% greater or less than the surface energy of the panels at the interface.

13. A method as in claim 9 wherein the sealant material is configured to, during the exposing step, maintain a viscosity of below about 5000centipoise for between about 15seconds and about 5minutes, the sealant material includes an encapsulated curing agent or curing agent accelerator, or a combination of both.

14. A method as in claim 9 wherein the sealant material is located upon a surface of one of the panels, but spaced away from the interface, and, during the exposing step flows to cover the interface.

15. A method as in claim 9 wherein:

(i) the sealant material is attached to a trim piece during locating of the sealant material adjacent the interface;

(ii) the sealant material includes magnetic particles for assisting in locating the sealant material adjacent the interface;

(iii) the sealant material has a U-shaped cross-section;

(iv) the sealant material, upon placement adjacent the interface, has a cantilevered portion;

(v) the sealant material has braided configuration;

or

(vi) any combination thereof.

16. A method of sealing an interface, the method comprising:

providing a sealant material;

locating the sealant material adjacent to the interface, the sealant material including pieces of blocking material;

exposing the sealant material to an elevated temperature such that the sealant material flows adjacent the interface wherein the pieces of blocking material prevent bubbles from penetrating through the sealant material to an outwardly facing surface of the sealant material; and

curing the sealant material to seal the interface.

17. A method as in claim 16 wherein the pieces are selected from flakes or platelets.

18. A method as in claim 16 wherein the pieces are formed at least partially of PET, polyamide, glass or ceramic.

19. A method as in claim 16, wherein the pieces are formed at least partially of PET.

20. A method as in claim 16, wherein the interface forms a portion of a roof ditch of the automotive vehicle.