Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Mixing of two or more solid polymers; mixing of solid...
Reexamination Certificate
2002-04-19
2004-05-11
Dawson, Robert (Department: 1712)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Mixing of two or more solid polymers; mixing of solid...
C523S445000, C523S457000, C523S458000, C523S466000, C523S468000, C525S528000, C525S529000, C525S920000, C528S121000, C528S123000
Reexamination Certificate
active
06734263
ABSTRACT:
FIELD OF THE INVENTION
The invention relates to polymeric materials. More specifically, the invention relates to non-polyvinyl chloride interpenetrating polymer network materials comprising epoxy urethane acrylates.
BACKGROUND OF THE INVENTION
Noise, vibration and harshness (NVH) that occurs during motor vehicle movement detracts from the consumer's enjoyment of driving and riding in the vehicle. The automotive industry is continually expending considerable money and effort searching for solutions to the problems posed by NVH.
A commonly explored remedy is application of an NVH damping composition to vehicle components. An optimal composition for reducing vehicle NVH must adhere to materials such as E coated metal, cast iron, aluminum and oily steel. Application of such a composition may be required at any stage of vehicle assembly, and thus should be in a suitable form such as paintable, pumpable, extrudable as a bead, swirl sprayable or airless sprayable. Importantly, an optimal composition requires uniform sound absorption over wide temperature ranges experienced during vehicle construction, coating, transport, storage and use.
Presently available compositions applied to reduce NVH problems have disadvantages including short shelf life, limited use conditions, relatively low adhesive strength and impact resistance and required use of volatile organic compounds in synthesis or application. Further, multiple compositions are often required for different NVH reducing applications such as seam sealing, NVH patches or body reinforcement. This limitation increases cost due to multiple formulation requirements and the necessity of duplicative application equipment. Thus, there is a continuing need for a composition providing effective NVH damping.
SUMMARY OF THE INVENTION
A composition that forms a non-polyvinyl chloride interpenetrating polymer network material with insulating and adhesive properties when cured is provided. A curable composition is provided that includes a resin component and a hardener component wherein the resin component includes an acrylated urethane oligomer and a liquid epoxy resin; and the hardener component includes an amine. Optionally, the resin, the hardener or both include a filler. The resin component may further include an epoxy silane, a flexible liquid epoxy resin, a reactive flexible epoxy diluent and a combination thereof. The hardener component may further include an accelerator, a heat-activated latent curing agent and a combination thereof.
An inventive process is provided for making a cured material including the steps of providing a resin component comprising an acrylated urethane oligomer and a liquid epoxy resin; providing a hardener component comprising an amine; mixing the resin component and the hardener component to obtain a curable composition; and incubating the curable composition at a temperature for a time sufficient for a cure reaction to occur. Optionally, the resin component, the hardener component or both include a filler. The resin component may further include an epoxy silane, a flexible liquid epoxy resin, a reactive flexible epoxy diluent and a combination thereof. The hardener component may further include an accelerator, a heat-activated latent curing agent and a combination thereof. Typically, the composition is cured at a temperature ranging from 15° C. to 250° C.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides compositions for a curable material which forms a non-polyvinyl chloride interpenetrating polymer network.
An interpenetrating network, formed by curing a mix of different types of monomers, provides synergistic advantages over the individual polymers. (Interpenetrating Polymer Networks, Klemper, D., Sperling, L. H. and Utraki, L. A., Eds., American Chemical Society Advances in Chemistry Series No. 239, 1994) For example, a curable composition of the present invention forms an interpentrating network having uniform sound absorption over a wide temperature range, improved sound absorption for the same thickness ratio compared to other traditional materials and improved corrosion resistance. An inventive curable composition has the advantage of allowing versatility in choosing a cure method, a room temperature, elevated temperature or combination cure being effective. An interpenetrating network formed by curing an inventive composition further provides enhanced non-fogging properties, abrasion resistance, stone chip resistance, adhesion and flexural strength.
A polymeric material is formed by combining a resin component and a hardener component and curing the mixture. A curable composition comprises: a urethane acrylate, a reactive epoxy compound and a reactive amine compound. The curing of the polymeric material is achieved by reaction of epoxy groups and urethane acrylates with amine functionalities. Epoxy groups suitable for formation of the polymeric material are provided by various compounds illustratively including epoxy silane, liquid epoxy resin, flexible liquid epoxy resin and reactive flexible epoxy diluent.
Simultaneous cure rates of epoxy and urethane acrylate are controlled by the amine ratio to form an interpenetrating polymer network. The material is adhesive and some illustrative applications include insulation from, for example, noise, vibration or harshness; reinforcing agent; seam filling and binding of components. It is an aspect of the present invention that the curable material is pumpable.
As used herein the term “flexible liquid epoxy resin” is intended to mean an epoxy resin modified to provide flexibility in the cured network. For example, an epoxy resin is adducted with a reactive liquid rubber. In one embodiment of this, an oxirane group of an epoxy resin is reacted with a carboxyl terminated liquid nitrile rubber forming an epoxy ester. In another illustrative example, an epoxy resin is reacted with flexible diols such as propylene glycol or dipropylene glycol resulting in an epoxy with butoxy or propoxy side chains. In a further example, dimerized fatty acids are reacted with epoxy to form an epoxy ester which provides flexibility in the compositions of the present invention.
As used herein the term “reactive flexible epoxy diluent” is intended to mean an epoxy-based diluent that acts to reduce viscosity of the resin for ease of application before curing and that cross links as normal epoxy when mixed with hardener. An example of a flexible reactive epoxy diluent is a mono or di-functional epoxy of aliphatic or aromatic hydrocarbons with chain length greater than three carbons, branched or as substitutes on the aromatic ring.
As used herein the term “heat-activated latent curing agent” is intended to mean that curing agent is activated with heat to cure the resin while it remains stable at room temperature or below room temperature.
As used herein the term “flexible amidoamine” is intended to mean long chain amine with amid linkages on the backbone and blended with compatible aliphatic amine.
As used herein the term “flexible amine” is intended to mean an amine with ether linkages on the backbone.
As used herein the term “modified amine” is intended to mean an amine blended with bisphenol A and/or alkyl phenols to accelerate the amine epoxy reaction.
As used herein the term “hydrocarbon diluent” is intended to mean non-reactive viscosity modifier.
As used herein the term “flexible polyamide” is intended to mean amine terminated polymer with amide linkages.
A curable composition of the present invention includes a resin and a hardener. The resin includes an epoxy resin and an acrylated urethane oligomer; and the hardener includes a reactive amine.
A curable mixture composition of the present invention includes resin and hardener components where the resin component includes an epoxy silane, an acrylated urethane oligomer, a liquid epoxy resin, a flexible liquid epoxy resin, a reactive flexible epoxy diluent and a first filler; and the hardener component includes a reactive anine and a second filler.
In a preferred embodiment, the resin component includes an
Ahn Yushin
Eadara Rajan
Jacob Roy P.
Joseff Jori
Philip Biju
Aylward D.
Dawson Robert
Diversified Chemical Technologies, Inc.
Gifford, Krass, Groh Sprinkle, Anderson & Citkowski, P.C.
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