Activatable material and method of forming and using same
An activatable material and articles incorporating the same is disclosed. The activatable material includes an isocyanate and an isocyanate reactive compound. The isocyanate is typically blocked such that the activatable material is non-reactive at temperatures below about 100° C. The activatable material is preferably used for sealing, baffling, reinforcing, adhering, sound attenuation, sound damping or the like of an article of manufacture such as an automotive vehicle.
1 . A method of sealing, baffling or reinforcing a portion of an article of manufacture, the method comprising:
providing an activatable material, the activatable material including:
i) an isocyanate reactive component; and
ii) a blocked isocyanate component; and
inserting the activatable material disposed thereon into a cavity that is at least partially defined by a structural member of the article of manufacture; and
activating the activatable material by unblocking the blocked isocyanate component to bond the activatable material to surfaces of the structural member.
2 . A method as in claim 1 wherein the activatable material is substantially tack-free to the touch.
3 . A method as in claim 1 wherein the activatable material, upon unblocking, forms a foam that exhibits a tensile strength greater than about 5 Mpa.
4 . A method as in claim 1 wherein the activatable material, upon unblocking, forms a foam that exhibits a compressive strength greater than about 6 Mpa.
5 . A method as in claim 1 wherein the activatable material, upon unblocking, forms a foam that has a density greater than about 0.1 g/cc and less than about 1.0 g/cc.
6 . A method as in claim 1 wherein the activatable material, upon unblocking, expands to a volume at least 50% greater than a volume of the activatable material in the unexpanded state
7 . A method as in claim 1 wherein the isocyanate component is blocked with a blocking agent selected from a pyrazole, a ketoxime, an acid ester, a caprolactam, an alkylated phenol or a combination thereof.
8 . A method as in claim 1 wherein the activatable material includes an epoxy resin.
9 . A method of sealing, baffling or reinforcing a portion of an automotive vehicle, the method comprising:
providing an activatable material, the activatable material including:
i) an isocyanate reactive component; and
iii) a blocked isocyanate component; and
applying the activatable material to a surface of a carrier member;
inserting the carrier member with the activatable material disposed thereon into a cavity that is at least partially defined by a structural member of the automotive vehicle; and
activating the activatable material at a temperature greater than about 100° C. to form the activatable material into a foam that bonds to surfaces of the structural member.
10 . A method as in claim 9 wherein the activatable material is substantially tack-free to the touch.
11 . A method as in claim 9 wherein the carrier is formed of a polyamide.
12 . A method as in claim 9 wherein the foam that exhibits a tensile strength greater than about 5 Mpa and a compressive strength greater than about 6 Mpa.
13 . A method as in claim 9 wherein the foam that has a density greater than about 0.1 g/cc and less than about 1.0 g/cc.
14 . A method as in claim 9 wherein the activatable material, upon activation, expands to a volume at least 50% greater than a volume of the activatable material in the unexpanded state
15 . A method as in claim 9 wherein the isocyanate component is blocked with a blocking agent selected from a pyrazole, a ketoxime, an acid ester, a caprolactam, an alkylated phenol or a combination thereof.
16 . A method as in claim 9 wherein the activatable material includes an epoxy resin.
17 . A method of sealing, baffling or reinforcing a portion of an automotive vehicle, the method comprising:
providing an activatable material, the activatable material including:
i) an isocyanate reactive component; and
ii) a blocked isocyanate component; and
applying the activatable material to a surface of a plastic carrier member, the plastic carrier member including a plurality of ribs;
inserting the carrier member with the activatable material disposed thereon into a cavity that is at least partially defined by a structural member of the automotive vehicle; and
activating the activatable material in an e-coat, paint or primer oven at a temperature greater than about 100° C. to form the activatable material into a foam that bonds to surfaces of the structural member wherein:
i. the foam exhibit a tensile strength greater than about 8 Mpa; and
ii. the foam has a density greater than about 0.3 g/cc.
18 . A method as in claim 17 wherein the activatable material is substantially tack-free to the touch.
19 . A method as in claim 18 wherein the carrier is formed of a polyamide, the foam that exhibits a compressive strength greater than about 10 Mpa, the foam has a density greater than about 0.3 g/cc and less than about 0.6 g/cc wherein the activatable material, upon activation, expands to a volume at least 50% greater than a volume of the activatable material in the unexpanded state and wherein the isocyanate component is blocked with a blocking agent selected from a pyrazole, a ketoxime, an acid ester, a caprolactam, an alkylated phenol or a combination thereof.
20 . A method as in claim 19 wherein the activatable material includes an epoxy resin.