Synthetic material and methods of forming and applying same
View Patent ↗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.
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.