Abstract: A polyurethane adhesive which is useful in bonding porous and non-porous surfaces is provided. The adhesive is especially useful in bonding windshield glass into automotive frames under a variety of environmental conditions, particularly in after market windshield replacement applications. The polyurethane includes at least one urethane prepolymer which is based on at least one thermoplastic polyol. In one embodiment, the urethane prepolymer may be formed from one or more polyisocyanates, one or more polyetherpolyols and one or more thermoplastic polyesterpolyols, wherein the prepolymer has a free isocyanate content of from about 0.6 to about 3.5% by weight, based on the weight of the polyurethane. In another embodiment, a one-part adhesive composition is provided which includes an isocyanate-functional and thermoplastic polyurethane prepolymer having a free isocyanate content of from about 0.6 to about 3.

Abstract: A physical barrier for sealing an orifice in a panel member is presented. The physical barrier includes a carrier that has one or more locating pins mounted on it. The pins are adapted to locate the carrier in the orifice. The physical barrier also includes a sealing material attached to the carrier. Also included is a method of installing the physical barrier into an orifice of a panel member.

Abstract: A method for installing a constrained layer damper on a product of manufacture is disclosed. The method includes applying a layer of first polymeric material to a substrate of the product, wherein the first polymeric material is visco-elastic when solidified. Then, a second layer of polymeric material, which is stiff when solidified, is applied to the first polymeric material such that said first polymeric material is constrained between the second polymeric material and the substrate of the product. At least one of the layers of polymeric materials is dispensed in fluid form during the manufacture of the product from a bulk source of fluid material. The polymeric materials are chosen such that they do not require the application of heat above room temperature to solidify.

Abstract: A combined baffle and reinforcing assembly is provided for use within the cavity of a structural member to dampen acoustic transmissions through the cavity and provide reinforcement in a direction transverse to the longitudinal axis of the structural member. The assembly includes a synthetic carrier which includes an interior area, marginal rim, and an attachment member preferably in the form of a clip for insertion to the corresponding hole in the wall of the structural member, and a circumscribing and continuous band of reinforcing material extending around the periphery of the carrier. The assembly may be economically manufactured by co-injection molding or insert molding of the thermally expansible material around the carrier. The marginal rim of the carrier may include base wall and a support flange for receiving the thermally expansible material thereon.

Abstract: Heat-expandable molded synthetic resin seal and baffle components adapted for use in automobile body cavities or the like are provided which are designed to preferentially expand upon heating in desired directions and to a desired degree, in order to properly seal irregular or special cavity shapes. The molded components of the invention have selected body surface portions thereof UV crosslinked to a depth of up to about 0.5 mm, while other portions of the molded body are not crosslinked; upon heating, the crosslinked portions expand at a slower rate and to a lesser extent than non-crosslinked body portions. The preferred synthetic resin includes a grafted anhydride polymer, a terminal epoxide polymer additive, a blowing agent, a UV photoinitiator and a UV crosslinkable resin system.

Abstract: A reinforcing assembly for use with roll bars adapted to be mounted to motor vehicles such as an automobile. The reinforcing assembly includes a heat-expandable synthetic resin reinforcing member and a retainer configured to attach the member to the interior of a two-piece telescopically interfitting tubular roll bar construction. Upon heating, the reinforcing member expands to form a seal between the two roll bar tube sections thereby providing sound-reduction and stability of the roll bar assembly.

Abstract: An expansible reinforcer for reinforcing a hollow structural member of an automobile, aircraft, boat, etc. is provided. The reinforcer is flexible/bendable and comprises a synthetic, resin-based expansible reinforcing material secured thereto. In a preferred embodiment, the reinforcer comprises a plurality of supports pivotally connected to one another in a train-like arrangement. The reinforcing material is formed of a thermally expansible composition which preferably has an expansion temperature similar to the temperatures achieved in specific stages of a particular manufacturing process (e.g., such as the temperature at which the paint bake or powder bake stage is carried out in the automobile manufacturing process). The inventive reinforcer is capable of being fed into the opening of a tight cavity on a structural member so as to provide uniform reinforcement of the structural member.

Abstract: A method is provided for adhering a polyurethane-based sealant or adhesive to a substrate. The method comprises: i) applying an aqueous primer solution onto a substrate, the primer solution comprising water, an aminotitanate compound, and preferably an epoxysilane compound having at least one epoxy group and at least two alkoxy groups; ii) applying a polyurethane adhesive or sealant to the primer-treated substrate; and iii) forming a reaction product of the primer and the polyurethane. Also provided are a substrate having a layer of a polyurethane adhesive or sealant, and a stabilized aqueous primer solution containing an epoxysilane compound and an aminotitanate compound.

Abstract: An expansible reinforcer for reinforcing a hollow structural member of an automobile, aircraft, boat, etc. is provided. The reinforcer is flexible/bendable and comprises a synthetic, resin-based expansible reinforcing material secured thereto. In a preferred embodiment, the reinforcer comprises a plurality of supports pivotally connected to one another in a train-like arrangement. The reinforcing material is formed of a thermally expansible composition which preferably has an expansion temperature similar to the temperatures achieved in specific stages of a particular manufacturing process (e.g., such as the temperature at which the paint bake or powder bake stage is carried out in the automobile manufacturing process). The inventive reinforcer is capable of being fed into the opening of a tight cavity on a structural member so as to provide uniform reinforcement of the structural member.

Abstract: A reinforced structural member is provided which includes a reinforcing member received in the cavity of a structural member. The reinforcing member includes a carrier having divergent, intersecting legs which preferably engage and rest upon the structural member, a thermally expandable reinforcing material, and a fastener for coupling the reinforcing material to the carrier. The thermally expandable reinforcing material is preferably provided as separate elements positioned on the carrier, whereby upon activation by heat, the expandable material melts, foams and expands so that after curing, the structural member is bonded to the carrier. The shape of the carrier in combination with the expanded reinforcing material serves to stiffen and reinforce the structural member. The thermally expandable material is preferably initially dry and non-tacky, and the fasteners serves to maintain the relative position of the reinforcing material elements on the carrier prior to activation of the reinforcing material.

Abstract: A baffle may conform to and be magnetically coupled to a body having a ferromagnetic component in proximity to the baffle. The baffle includes a first layer of a flexible thermally expansible baffle material which expands when subjected to an elevated temperature, and a second layer of a flexible magnetic material. The baffle may thereby be flexed to conform to an irregular or curved surface. In addition, the baffle may be preformed to provide an irregular or arcuate portion to conform to the body on which it is placed. The magnetic attachment facilitates attachment and removal without the need to provide holes in the body, and upon heating and expansion of the baffle, the baffle material expands to fill cavities and adhere to the inside wall surface of the body on which it is received.

Abstract: A combined baffle and reinforcing assembly is provided for use within the cavity of a structural member to dampen acoustic transmissions through the cavity and provide reinforcement in a direction transverse to the longitudinal axis of the structural member. The assembly includes a synthetic carrier which includes an interior area, marginal rim, and an attachment member preferably in the form of a clip for insertion to the corresponding hole in the wall of the structural member, and a circumscribing and continuous band of reinforcing material extending around the periphery of the carrier. The assembly may be economically manufactured by co-injection molding or insert molding of the thermally expansible material around the carrier. The marginal rim of the carrier may include base wall and a support flange for receiving the thermally expansible material thereon.

Abstract: An expansible foaming reinforcing member for reinforcing a hollow structural member of an automobile, aircraft, boat, etc. is provided. The reinforcing member includes a synthetic, resin-based expansible reinforcing material secured to a carrier which maintains the reinforcing member at the desired location within the structural member until thermal expansion. The reinforcing material is formed of a thermally expansible composition which preferably has an expansion temperature similar to the temperatures achieved in specific stages of a particular manufacturing process (e.g., such as the temperature at which the paint bake or powder bake stage is carried out in the automobile manufacturing process). The reinforcing material of the inventive reinforcing member comprises a plurality of spaced-apart fins or ribs. During heat activation, heated air can travel between the ribs, thus allowing a greater surface area of the reinforcing material to be exposed to heat leading to improved expansion.

Abstract: Expandable sealant and baffle compositions and methods of forming and using such compositions are provided wherein the compositions comprise a first thermoplastic resin, an epoxy resin, preferably a second thermoplastic resin different from the first thermoplastic resin, and optionally a compound selected from the group consisting of pigments, blowing agents, catalysts, curing agents, reinforcers, and mixtures thereof. The resulting compositions are formed as self-sustaining bodies which can be heat-expanded into a lightweight, high strength product for sealing hollow structural members of vehicles, substantially decreasing the noise which travels along the length of those members as well as strengthening those members with minimal increases in their weights. In a preferred embodiment, the first thermoplastic resin is an SBS block co-polymer, the epoxy resin is a bisphenol A-based liquid epoxy resin, the second thermoplastic resin is a polystyrene, and the reinforcer is hydrated amorphous silica.

Abstract: An expandable baffle for sealing a cavity of an automobile is provided. The baffle includes a thermally expandable sealing material which has an expansion temperature similar to the temperatures achieved in specific stages of the automotive manufacturing processes (e.g., the paint bake stage). The inventive baffle further includes a support for the sealing material which maintains the material at the desired location within the cavity until thermal expansion. The support is formed of a material having a melting point higher than the thermal expansion temperature of the sealing material. In one embodiment, the support comprises a pair of solid, spaced-apart sidewalls that “bow” upon expansion of the sealing material. In an alternate embodiment, the sidewalls include a plurality of openings formed therein through which the sealing material flows during thermal expansion.

Abstract: Expandable sealant and baffle compositions and methods of forming and using such compositions are provided wherein the compositions comprise a first thermoplastic resin, an epoxy resin, preferably a second thermoplastic resin different from the first thermoplastic resin, and optionally a compound selected from the group consisting of pigments, blowing agents, catalysts, curing agents, reinforcers, and mixtures thereof. The resulting compositions are formed as self-sustaining bodies which can be heat-expanded into a lightweight, high strength product for sealing hollow structural members of vehicles, substantially decreasing the noise which travels along the length of those members as well as strengthening those members with minimal increases in their weights. In a preferred embodiment, the first thermoplastic resin is an SBS block co-polymer, the epoxy resin is a bisphenol A-based liquid epoxy resin, the second thermoplastic resin is a polystyrene, and the reinforcer is hydrated amorphous silica.

Abstract: Heat-expandable molded synthetic resin seal and baffle components adapted for use in automobile body cavities or the like are provided which are designed to preferentially expand upon heating in desired directions and to a desired degree, in order to properly seal irregular or special cavity shapes. The molded components of the invention have selected body surface portions thereof UV crosslinked to a depth of up to about 0.5 mm, while other portions of the molded body are not crosslinked; upon heating, the crosslinked portions expand at a slower rate and to a lesser extent than non-crosslinked body portions. The preferred synthetic resin includes a grafted anhydride polymer, a terminal epoxide polymer additive, a blowing agent, a UV photoinitiator and a UV crosslinkable resin system.

Abstract: A reinforcing member for a structural component such as a rail or channel of a vehicle is provided which includes a carrier and a thermally expansible structural reinforcing material element which is fastened to the carrier by mechanical fixation or an adhesive. The mechanical fixation may be provided by a flange or other mechanical connection on the carrier or by a fastener such as a push pin extending through aligned holes and openings in the carrier and foamable material. The push pins are preferably of a synthetic resin material which more closely approximates the heat conductivity of the foamable material when the latter is activated by heat, and is sufficiently yieldable to absorb impacts to the foamable material during installation.

Abstract: An expansion temperature tolerant, dry, expandable sealant and baffle is provided which is capable of undergoing a desired degree of full expansion when an automobile body containing the sealant and baffle product is conveyed through a conventional bake and/or curing oven. The sealant and baffle product is fully expandable over a wider temperature and time range than heretofore available expandable baffle products. The composition for preparation of a molded expandable sealant and baffle component includes a grafted anhydride polymer, an epoxide terminated additive polymer which are capable of reacting with the grafted anhydride polymer and a blowing agent.