ACTIVATABLE MATERIAL FOR SEALING,
BAFFLING OR REINFORCING AND
METHOD OF FORMING SAME
FIELD OF THE INVENTION
The present invention relates generally to an activatable material, a method of forming the activatable material and a method of using the activatable material for sealing, baffling, adhering or reinforcing of components of articles of manufacture such as automotive vehicles.
BACKGROUND OF THE INVENTION
For many years industry, and particularly the transportation industry has been concerned with sealing, baffling, acoustic attenuation, adhesion and reinforcement of articles of manufacture such as automotive vehicles. In turn, industry has developed a wide variety of materials for providing such sealing, baffling, adhesion and reinforcement. The present invention, therefore, seeks to provide an improved material for sealing, baffling, adhesion or reinforcement, a method of forming the improved material and a method for use of the improved material for reinforcing, sealing, adhering or baffling.
SUMMARY OF THE INVENTION
Accordingly, a method of adhesion is disclosed. The method comprises provision of an activatable material. The activatable material typically includes epoxy resin; epoxy/ elastomer adduct; a core/shell polymer impact modifier; and a curing agent. The activatable material is typically located adjacent a first surface and a second surface of an article of manufacture. The activatable material is then typically activated to bond the activatable material to the first surface and second surface,
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of members to be joined in accordance with an aspect of the present inventions
FIG. 2 is a sectional view of an activatable material being applied to the members of FIG. 1 in accordance with an aspect of the present invention.
FIG. 3 is a sectional view of an activatable material after applications and activation andjoining the members of FIGS. 1 and 2 in accordance with the aspect of the present invention.
The present invention is predicated upon provision of an improved activatable material, and articles incorporating the same. The activatable material preferably assists in providing structural reinforcement, adhesion, sealing, baffling, vibrational damping properties or a combination thereof within a cavity of, or upon a surface of a structure, or to one or more structural members (e.g., a body panel or structural member) of an article of manufacture (e.g., an automotive vehicle). In one particular embodiment, the activatable material has been found particularly useful for joining and/or adhering to surfaces of metal components (e.g., metal vehicle panels). As used herein, the phrase activatable material includes any material that may be activated to melt, flow, cure (e.g., thermoset), expand, foam or a combination thereof by an ambient condition or another condition, For example, the material may expand, foam, flow, melt, cure, any combination thereof
or the like upon exposure to a condition such a heat, pressure, chemical exposure, combinations thereof or the like.
The activatable material typically includes a polymeric admixture, an impact modifier and one or a combination of a 5 blowing agent, a curing agent and a filler. The activatable material preferably includes at least three of the following:
a. about 2 to about 80 percent by weight epoxy resin;
b. about 2 to about 70 percent by weight polymer (e.g., epoxy)/elastomer adduct;
10 c. one or more additional polymers, which typically include a one or more ethylene polymers or copolymers;
d. about 2 to about 70 percent by weight impact modifier;
e. about 0.1 to about 30 percent by weight thermoplastic 15 polyether;
f. up to about 5 parts by weight of a blowing agent;
g. up to about 7 parts by weight of a curing agent; and
h. a filler.
The concentration may be higher or lower depending upon 20 the intended application of the activatable material. In a preferred aspect of the invention, the impact modifier includes one or more core/shell polymers, although not necessarily required.
The activatable material of the present invention may be
25 applied to various articles of manufacture for adhering members to each other adding structural integrity to portions or members of articles, for providing acoustical damping to the articles or for sealing the articles. Examples of such articles of manufacture include, without limitation, household or indus
30 trial appliances, furniture, storage containers, buildings, structures or the like. In preferred embodiments, the activatable material is applied to portions of an automotive vehicle such as body components (e.g., panels such as inner and/or outer body panels) or frame members (e.g., a vehicle frame
35 rail) of the automotive vehicle. One method of the present invention contemplates applying the activatable material to a surface of one of the above structures in an unexpanded or partially expanded state and activating the material for expanding (e.g., foaming) it to a volume greater than its
40 volume in the unexpanded state (e.g., at least 5% greater, at least 50% greater, at least 200% greater, at least 1000% greater, at least 2000% greater, at least 5000% greater or higher). Itis also contemplated that the volume of the material may be less after activation due to curing (e.g., cross-linking)
45 for foamed or unfoamed versions of the activatable material. Percentages herein refer to weight percent, unless otherwise indicated.
50 Epoxy resin is used herein to mean any of the conventional dimeric, oligomeric or polymeric epoxy materials containing at least one epoxy functional group. Moreover, the term epoxy resin can be used to denote one epoxy resin or a combination of multiple epoxy resins. The polymer-based
55 materials may be epoxy-containing materials having one or more oxirane rings polymerizable by a ring opening reaction. In preferred embodiments, the activatable material includes up to about 80% or more of an epoxy resin. More preferably, the expandable includes between about 2% and 70% by
60 weight epoxy resin and still more preferably between about 4% and 30% by weight epoxy resin, Of course, amounts of epoxy resin may be greater or lower depending upon the intended application of the activatable material. As an example, it is contemplated that weight percentages may be
65 lower or higher when other ingredients such as the adduct, filler, alternative polymers, combinations thereof or the like are used in greater or lesser weight percentages.