Stock material or miscellaneous articles – Composite – Of epoxy ether
Reexamination Certificate
2002-02-19
2004-06-15
Jagannathan, Vasu (Department: 1712)
Stock material or miscellaneous articles
Composite
Of epoxy ether
C523S400000, C523S440000, C523S457000, C523S458000, C525S438000, C525S533000
Reexamination Certificate
active
06749939
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to compositions having sealing and sound dampening properties and related processes. In particular, the present invention relates to compositions having sealing and sound dampening properties that can be applied in a body shop via spraying.
BACKGROUND & DISCUSSION
Sealants and sound dampeners typically are applied to a variety of areas in automobile bodies such as interior floor pans, firewalls, decklids, and is between the inner and outer panels of doors. Conventionally, sealants have comprised plastisols that can be applied between and upon metal seams, welds and within hollow cavities of autobodies. Generally, sealants are used to impart structural integrity and to create a barrier against dirt and exhaust gases. Sound dampeners typically are pre-cut pieces of fibrous asphaltic material or aluminum constrained butylene rubber used to dampen road and engine noise that can be transmitted through the autobody substrates.
A sprayable coating composition having vibration and harsh noise reduction or absorption properties is disclosed in International Application WO 99/16840. The sprayable coating composition comprises a mixture of flexible epoxy resins and rigid epoxy resins. The flexible epoxy resins are defined as those having elastomeric chains in the backbone; and the rigid epoxy resins are defined as those epoxy resins having bisphenol moieties in the backbone. The mixture of the flexible and rigid epoxy resins should be such that the peak glass transition temperature of the composition is 10° C. or greater.
Conventionally, sealants and sound dampeners are applied to some automotive parts in the paint shop area of an automobile assembly plant which is typically located downstream from the electrocoat tank in the automotive coating process. The application of sealants and sound dampeners in the paint shop area can result in fingerprints, dirt and/or overspray on the automotive part which must be removed prior to subsequent application of primer and/or top coatings.
The body shop is the area of an automobile assembly plant which is located upstream from and can include the electrocoat tank. In a body shop, any dirt, fingerprints, and/or overspray on the automotive part resulting from the application of sealants and sound dampeners could be washed away in the pretreatment wash cycle. It, therefore, would be advantageous to provide a composition having sealing and sound dampening properties suitable for application in the body shop area of the automotive assembly plants.
SUMMARY OF THE INVENTION
In one embodiment, the present invention provides a composition having improved sealing and sound dampening properties comprising:
(a) one or more polyepoxides comprising at least two epoxide groups per molecule;
(b) a thermoplastic polyester polymer;
(c) a curing agent adapted to react with the polyepoxides;
(d) inorganic particles having an oil absorption value of less than 70 as determined in accordance with ASTM D 281-95; and
(e) inorganic microparticles different from the inorganic particles (d), the inorganic microparticles having an average particle size prior to incorporation into the composition ranging from 0.5 to 200 microns.
In another embodiment, the present invention provides a multilayer composite comprising a weldable primer layer formed from a weldable primer composition, and a second layer having improved sealing and sound dampening properties formed from a second composition over at least a portion of the weldable primer layer, the second composition comprising:
(a) one or more polyepoxides comprising at least two epoxide groups per molecule;
(b) a thermoplastic polyester polymer;
(c) a curing agent adapted to react with the polyepoxide (a);
(d) inorganic particles having an oil absorption value of less than 70 as determined in accordance with ASTM D 281-95; and
(e) inorganic microparticles different from the inorganic particles (d), the inorganic microparticles having an average particle size prior to incorporation into the composition ranging from 0.5 to 200 microns.
In yet another embodiment, the invention provides a coated metallic substrate comprising:
a metallic substrate, and a composition having sealing and sound dampening properties over at least a portion of the substrate, said composition comprising:
(a) one or more polyepoxides comprising at least two epoxide groups per molecule;
(b) a thermoplastic polyester polymer;
(c) a curing agent adapted to react with the polyepoxides (a);
(d) inorganic particles having an oil absorption value of less than 70 as determined in accordance with ASTM D 281-95; and
(e) inorganic microparticles different from the inorganic particles (d), the inorganic microparticles having an average particle size prior to incorporation into the composition ranging from 0.5 to 200 microns.
Additionally, the present invention provides a coated metallic substrate comprising:
a metallic substrate;
a weldable primer layer formed from a weldable primer composition deposited over at least a portion of the substrate; and
a second layer formed from a second composition having sealing and sound dampening properties deposited over at least a portion of the weldable primer layer, the second composition comprising:
(a) one or more polyepoxides comprising at least two epoxide groups per molecule;
(b) a thermoplastic polyester polymer;
(c) a curing agent adapted to react with the polyepoxides (a);
(d) inorganic particles having an oil absorption of less than 70; and
(e) inorganic microparticles different from the inorganic particles (d), the inorganic microparticles having an average particle size prior to incorporation into the composition ranging from 0.5 to 200 microns.
In another embodiment, the invention provides a method for forming a coating having sealing and sound dampening properties on a metallic substrate comprising the steps of:
(a) providing a metallic substrate having two major surfaces,
(b) applying a composition to at least a portion of one of the major surfaces of the substrate, said composition comprising:
(1) one or more polyepoxides comprising at least two epoxide groups per molecule;
(2) a thermoplastic polyester polymer;
(3) a curing agent adapted to react with the polyepoxides (1);
(4) inorganic particles having an oil absorption value of less than 70 as determined in accordance with ASTM D 281-95; and
(5) inorganic microparticles different from the inorganic particles (4), the inorganic microparticles having an average particle size prior to incorporation into the composition ranging from 0.5 to 200 microns; and
(c) curing the applied composition, wherein the coated substrate of step (c) has a sound dampening value greater than 0.030 Oberst dissipation factor as measured at 200 Hz at 25° C. in accordance with ASTM E-756-98.
In yet another embodiment, the invention provides a composition having sealing and sound dampening properties comprising:
(a) one or more polyepoxides comprising at least two epoxide groups;
(b) a thermoplastic polyester polymer;
(c) a curing agent adapted to react with the polyepoxide (a); and
(d) inorganic particles having an oil absorption value of less than 70 as determined in accordance with ASTM D 281-95,
the improvement comprising the inclusion in the composition of inorganic microparticles different from the inorganic particles (d) in an amount sufficient to provide corrosion resistance properties as measured in accordance with Chrysler Test Method LP-463PB-10-01 which are superior to the corrosion resistance properties of the same composition which does not contain said inorganic microparticles, the inorganic microparticles having an average particle size prior to incorporation into the composition ranging from 0.5 to 200 microns.
DETAILED DESCRIPTION OF THE INVENTION
Other than in the operating examples, or where otherwise indicated, all numbers expressing quantities of ingredients, reaction conditions and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about”. Accordingly, unles
Desai Umesh C.
Hartman Marvis E.
Palermo Anthony C.
Jagannathan Vasu
Miles Jacques B.
PPG Industries Ohio Inc.
Zimmer Marc S
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