US20060142403A1 - Pasty heat-expandable filler composition and method of sound insulation by filling closed section of car body member - Google Patents

Pasty heat-expandable filler composition and method of sound insulation by filling closed section of car body member Download PDF

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Publication number
US20060142403A1
US20060142403A1 US10/559,477 US55947705A US2006142403A1 US 20060142403 A1 US20060142403 A1 US 20060142403A1 US 55947705 A US55947705 A US 55947705A US 2006142403 A1 US2006142403 A1 US 2006142403A1
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Prior art keywords
injection composition
weight
blowing
composition
damming
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Yutaka Sugiura
Masaki Ukai
Kiyoyuki Gotou
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Sunstar Giken KK
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Sunstar Giken KK
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Assigned to SUNSTAR GIKEN KABUSHIKI KAISHA reassignment SUNSTAR GIKEN KABUSHIKI KAISHA ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: GOTOU, KIYOYUKI, SUGIURA, YUTAKA, UKAI, MASAKI
Publication of US20060142403A1 publication Critical patent/US20060142403A1/en
Priority to US12/659,507 priority Critical patent/US9045161B2/en
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
    • C08J9/06—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a chemical blowing agent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/001—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material
    • B62D29/002—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material a foamable synthetic material or metal being added in situ
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/0061—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof characterized by the use of several polymeric components
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L21/00—Compositions of unspecified rubbers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2321/00—Characterised by the use of unspecified rubbers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2363/00—Characterised by the use of epoxy resins; Derivatives of epoxy resins
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2421/00—Characterised by the use of unspecified rubbers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2463/00—Characterised by the use of epoxy resins; Derivatives of epoxy resins

Definitions

  • the present invention relates to a paste form heat-blowing injection composition and a method for injecting and soundproofing a closed section of an automobile body part.
  • the present invention relates to a method for injecting an insulation wall of a body part having a closed section frame for shutting out wind noise during driving of an automobile, and an automatic injecting type paste form heat-blowing injection composition used for forming an insulation wall in the above method.
  • the present invention relates to an automatic injecting type paste form heat-curable damming injection composition which prevents the sag of the heat-blowing injection composition during the heat-blowing of said composition to form the insulation wall.
  • a windshield pillar A pillar
  • a center pillar B pillar
  • a rear pillar C pillar
  • a wheel arch tire housing
  • a side sill a side sill
  • the closed section of such a part is usually filled with a foam for shutting out noises (an insulation wall).
  • a prefoamed polyurethane foam is crammed into the closed section of an automobile body part by hands, or a shaped material of a heat-blowing injection composition is adhered to the inside surface of the closed section and then thermally foamed in a baking step.
  • a prefoamed polyurethane foam is crammed into the closed section of an automobile body part by hands, or a shaped material of a heat-blowing injection composition is adhered to the inside surface of the closed section and then thermally foamed in a baking step.
  • an automatic injecting type paste form heat-blowing injection composition was developed.
  • a composition which has an anti-stringy property during application, prevents sagging during thermal blowing and is foamed at a high expansion ratio
  • a composition which comprises a liquid rubber (for decreasing a viscosity and imparting adherence to an oil-surface steel plate), an unvulcanized rubber (for increasing an expansion ratio by virtue of the high retention of expansion gas), a curing agent and a curing accelerator, a softening agent (for lubricating rubber particles), a blowing agent and a blowing aid, a flake-form inorganic filler (for preventing sag and improving an anti-stringy property), and a thixotropic agent (for preventing sag) (see JP-B-3017571).
  • composition disclosed in this patent specification is applied in the form of beads at specified sites of a panel and then cured in a foamed state by heating in a baking oven in a subsequent step of electrodeposition coating.
  • the cured material exhibits good performances of soundproofing and shutting out wind noise.
  • An object of the present invention is to provide an automatic injecting type paste form heat-blowing injection composition with a high blowing performance, which is in superior to the conventional injection compositions, and which has an anti-stringy property during application and can prevent sag during thermal blowing.
  • Another object of the present invention is to provide a method for injecting and soundproofing a closed section of an automobile body part, which has a large closed sectional area and thus cannot be completely injected with a conventional paste form heat-blowing injection composition, for example, a B pillar which is substantially vertically held and has a large closed section.
  • a conventional paste form heat-blowing injection composition for example, a B pillar which is substantially vertically held and has a large closed section.
  • a further object of the present invention is to provide a paste form heat-curable damming injection composition which is suitably used as a damming material in the method of injecting and soundproofing a closed section of an automobile body part according to the present invention.
  • a paste form composition having a sufficient viscosity for maintaining an applied shape can be obtained when an epoxy resin as a thermally curable material and a latent curing agent thereof, and also a blowing agent are compounding in a composition comprising a partially crosslinked rubber, an unvulcanized rubber, a plasticizer, a thermoplastic resin and a crosslinking agent, and that such a paste form composition can be automatically applied, in particular, the partially crosslinked rubber contributes to an anti-stringy property during application, a film is formed by the thermal swelling of the plasticizer and the thermoplastic resin and the thermal crosslinking of the unvulcanized rubber with the crosslinking, and the thermal curing of the epoxy resin contributes to the toughness of the film and also the formation of foam cells.
  • the conventional composition uses a flake-form inorganic filler such as mica or talc to improve the anti-stringy property of the composition.
  • a flake-form inorganic filler such as mica or talc
  • the use of the flake-form inorganic filler may deteriorate the discharging and blowing properties of the composition.
  • the automatic injecting type paste form heat-blowing injection composition of the present invention can achieve the desired soundproofing effect, but the present inventors made further investigations and found the following:
  • the injection composition is applied to the pillar, in particular, a part of the pillar having a relatively large cross sectional area
  • the injection composition 1 of the present invention or the conventional injection composition is applied in the form of two rows of beads as shown in FIG. 1 ( 1 ), and then heated and foamed, the composition tends to sag and flow in the step of thermal blowing and form a foam 2 as shown in FIG. 1 ( 2 ) with insufficient injecting.
  • an automatic injecting type paste form heat-curable damming injection composition 3 is applied in the form of beads at a suitable position shown in FIG. 1 ( 2 ) to prevent such sagging of the paste form heat-blowing injection composition and then the paste form heat-blowing injection composition 1 is heated and foamed, a cured damming material 4 is formed and prevents the sagging of the injection composition so that a foam 5 shown in FIG. 1 ( 2 ), that is, an insulation wall is formed.
  • the composition of the damming injection composition 3 should be designed such that the damming injection composition 3 cures to gel prior to the occurrence of sagging of the injection composition 1 during heating and blowing of the injection composition and the gelled damming injection composition has shape maintenance for withstanding the pressure of the injection composition which sags and flows during thermal blowing.
  • the present invention has been completed based on the above findings.
  • the present invention provides:
  • an automatic injecting type paste form heat-blowing injection composition comprising a partially crosslinked rubber, an unvulcanized rubber, a crosslinking agent, a plasticizer, a thermoplastic resin, an epoxy resin and a latent curing agent thereof, and a blowing agent, which composition preferably has a viscosity of 30 to 500 Pa ⁇ s (at 20° C.) and a blowing start temperature of at least 100° C.;
  • an automatic injecting type paste form heat-blowing injection composition to a closed section of an automobile body part having a closed section frame, which is press molded in a body welding step of an automobile manufacturing line, prior to the assembling of the body part,
  • an automatic injecting type paste form heat-curable damming injection composition which preferably comprises a partially crosslinked rubber, a plasticizer, a thermoplastic resin, and optionally an epoxy resin and a latent curing agent thereof and has a viscosity of 30 to 500 Pa ⁇ s (at 20° C.), a gelation start temperature of 90° C. or less and a viscosity after gelation of at least 100,000 Pa ⁇ s, is applied in adjacent to the paste form heat-blowing injection composition or at a distance from the injection composition, thereby the sagging of the injection composition is prevented by the gelled damming injection composition when the insulation wall formed from the injection composition insufficiently fill the closed section because of the sagging of the injection composition during heating and blowing; and
  • an automatic injecting type paste form heat-curable damming injection composition comprising a partially crosslinked rubber, a plasticizer, a thermoplastic resin, and optionally an epoxy resin and a latent curing agent thereof.
  • FIG. 1 schematically explains the soundproofing effect achieved by the use of a paste form damming injection composition according to the present invention in the case of a member having a large cross sectional area.
  • FIG. 2 is a schematic perspective view of a member used in Example 1 and Comparative Examples 1 and 2 with showing sizes.
  • FIG. 3 schematically shows the angles of inclination of the member used in Example 1 and Comparative Examples 1 and 2, and the application position of a paste form damming injection composition according to the present invention.
  • FIG. 4 is a graph showing the gelation behavior according to dynamic viscoelastic measurement and the foaming behavior according to DSC of the paste form injection composition and the paste form damming injection composition used in Example 1 and Comparative Examples 1 and 2.
  • a partially crosslinked rubber used in the present invention means a diene rubber which is partially crosslinked or cured with a crosslinking agent such as divinylbenzene or sulfur.
  • a crosslinking agent such as divinylbenzene or sulfur.
  • the diene rubber include acrylonitrile-isoprene copolymer rubber (NIR), acrylonitrile-butadiene copolymer rubber (NBR), styrene-butadiene copolymer rubber (SBR), butadiene rubber (BR), isoprene rubber (IR), etc.
  • NIR acrylonitrile-isoprene copolymer rubber
  • NBR acrylonitrile-butadiene copolymer rubber
  • SBR styrene-butadiene copolymer rubber
  • BR butadiene rubber
  • IR isoprene rubber
  • the use of the partially crosslinked rubber can improve an anti-stringy property when the composition containing no flake-form inorganic filler is applied.
  • unvulcanized rubber examples include NIR, NBR, SBR, BR, IR, natural rubber, etc.
  • crosslinking agent used in the paste form heat-blowing injection composition of the present invention any conventional crosslinking agent can be used as long as it is activated by heating and crosslinks a rubber.
  • the crosslinking agent are organic peroxides (e.g. ketone peroxides, peroxyketals, hydroperoxides, dialkyl peroxides, phenyl peroxides, peroxyesters, peroxydicarbonates, etc.). These crosslinking agents may be used independently or as a mixture of two or more of them depending on heating conditions or desired properties of crosslinked materials.
  • a plasticizer used in the present invention may be any plasticizer that can swell or dissolve the partially crosslinked rubber, the unvulcanized rubber and a thermplastic resin which will be explained below.
  • plasticizer examples include phthalates such as di(2-ethylhexyl)phthalate, butylbenzyl phthalate, dinonyl phthalate, diisononyl phthalate, diisodecyl phthalate, diundecyl phthalate, diheptyl phthalate, butylphthalylbutyl glycolate, etc.; esters of aliphatic dibasic carboxylic acids such as dioctyl adipate, didecyl adipate, dioctyl sebacate, etc.; polyglycol esters of benzoic acid such as polyoxyethylene glycol dipenzoate, polyoxypropylene glycol dibenzoate, etc.; phosphates such as tributyl phosphate, tricresyl phosphate, etc.; hydrocarbons such as alkyl-substituted diphenyl, alkyl-substituted terphenyl, partially hydrogenated alky
  • thermoplastic resin used in the present invention is a resin which is present in the form of particles at room temperature and can be made swellable and soluble in the plasticizer above when heated.
  • plasticizer include acrylic resins such as polymers of alkyl acrylates (e.g. methyl acrylate, ethyl acrylate, butyl acrylate, 2-ethylhexyl acrylate, etc.) or alkyl methacrylate (e.g.
  • MBS resins methyl methacrylate-butadiene-styrene copolymer
  • AAS resins acrylonitrile-styrene-specific rubber cop
  • thermoplastic resin and the plasticizer may be used in amounts such that the composition has a gelation start temperature of 900C or less and a viscosity after gelation of at least 100,000 Pa ⁇ s at a gelling temperature.
  • An epoxy resin used in the present invention may be any epoxy resin that is used in this art field.
  • Specific examples of the epoxy resin include glycidyl ether epoxy resins, glycidyl ester epoxy resins, glycidyl amine epoxy resins, linear aliphatic epoxide epoxy resins, alicyclic epoxide epoxy resins, their modified derivatives such as rubber-modified epoxy resins, for example, reaction products of bisphenol epoxy resins (e.g.
  • diglycidyl ethers of bisphenol A, bisphenol F or bisphenol AD diglycidyl ethers of alkylene oxide adducts of bisphenol A, etc.
  • urethane-modified epoxy resins for example, reaction products of OH-containing epoxy resins (e.g. diglycidyl ether of bisphenol A, diglycidyl ether of aliphatic polyhydric alcohol, etc.) with urethane prepolymers having terminal NCO groups which are prepared by reacting polytetramethylene ether glycol (having a molecular weight of 500 to 5,000) and an excess amount of diisocyanates (e.g. tolylene diisocyanate, diphenylmethane diisocyanate, etc.), thiokol-modified epoxy resins, and so on.
  • OH-containing epoxy resins e.g. diglycidyl ether of bisphenol A, diglycidyl ether of aliphatic polyhydric alcohol, etc.
  • epoxy resins may be used independently or as a mixture of two or more of them.
  • a latent curing agent used in the present invention may be any conventional curing agent that exhibits a curing function by heating and can be activated usually at a temperature between 80 to 250° C.
  • Specific examples of the latent curing agent include dicyandiamide, 4,4′-diaminodiphenylsulfone, imidazole derivatives (e.g. 2-n-heptadecylimidazole, etc.), isophthalic dihydrazide, N,N-dialkylurea derivatives, N,N-dialkylthiourea derivatives, melamine derivatives, etc.
  • These curing agents may be used independently or as a mixture of two or more of them depending on curing conditions or their properties.
  • a blowing agent used in the paste form heat-blowing injection composition of the present invention may be any blowing agent that is decomposed by heating to generate gas.
  • the blowing agent include azo compounds (e.g. azodicarbonamide, etc.), nitroso compounds (e.g. N,N′-dinitrosopentamethylenetetramine, etc.), hydrazine compounds (e.g. diphenylsulfone-3,3′-disulfohydrazide, etc.), and so on.
  • These blowing agents may be used independently or as a mixture of two or more of them preferably in combination with blowing aids (e.g. urea, etc.).
  • the automatic injecting type paste form heat-blowing injection composition according to the present invention contains a partially crosslinked rubber, an unvulcanized rubber, a crosslinking agent, a plasticizer, a thermoplastic resin, an epoxy resin and a latent curing agent thereof, and a blowing agent and optionally a blowing aid.
  • the paste injection composition preferably has a viscosity of 30 to 500 Pa ⁇ s (at 20° C. and a shear rate of 430 sec ⁇ 1 ), and its blowing temperature is preferably adjusted at least 100° C., more preferably 110 to 140° C.
  • the paste injection composition of the present invention may optionally contain conventional additives such as thixtropic agent (e.g. organic bentonite, fumed silica, aluminum stearate, metal soap, caster oil derivatives, etc.), fillers (e.g. heavy calcium carbonate, surface-treated calcium carbonate, clay, silica, resin powder, fly ash, etc.), pigments (e.g. carbon black, titanium oxide, other inorganic pigments, etc.), dehydrating agents (e.g. calcium oxide, powder silica gel, etc.), and so on in suitable amounts.
  • thixtropic agent e.g. organic bentonite, fumed silica, aluminum stearate, metal soap, caster oil derivatives, etc.
  • fillers e.g. heavy calcium carbonate, surface-treated calcium carbonate, clay, silica, resin powder, fly ash, etc.
  • pigments e.g. carbon black, titanium oxide, other inorganic pigments, etc.
  • dehydrating agents e.g
  • a preferable formulation of the paste injection composition of the present invention are as follows (% is “a % by weight” based on the weight of the whole composition):
  • Preferable Formulation of Paste Injection Composition Partially crosslinked rubber 1-10%, preferably 3-7% Unvulcanized rubber 1-10%, preferably 3-7% Crosslinking agent 0.01-5%, preferably 0.02-0.6% Plasticizer 30-50%, preferable 30-40% Thermoplastic resin 1-15%, preferably 4-12% Epoxy resin 0.5-10%, preferably 1-7% Latent curing agent 0.05-5%, preferably 0.1-3% Blowing agent 1-10%, preferably 2-7% Additive(s) 25-45%, preferably 30-40%
  • the amount of the partially crosslinked rubber is less than 1%, the anti-stringy property of the composition may not be improved.
  • the amount of the partially crosslinked rubber exceeds 10%, a discharge property deteriorates and an expansion ratio tends to decrease.
  • an expansion ratio of the composition may be insufficient.
  • the amount of the unvulcanized rubber exceeds 10%, it may be difficult to achieve sufficient discharge and/or anti-stringy properties.
  • the amount of the plasticizer is less than 30%, the production of the composition is difficult, and a discharge property of the composition deteriorate.
  • amount of the plasticizer exceeds 50%, the liberated plasticizer tends to bleed out after curing to cause the shrinkage of the foam.
  • the amount of the thermoplastic resin is less than 1%, the formation of a film may be insufficient, and a sufficient expansion ratio may not be attained.
  • the amount of the thermoplastic resin exceeds 15%, the viscosity stability of the composition tends to greatly deteriorate so that the discharge property deteriorate.
  • the amount of the epoxy resin exceeds 10%, the elongation of the cured material of the composition tends to decrease so that the expansion ratio decreases, and the injecting property deteriorates.
  • the lower limit of the amount of the epoxy resin may not be particularly limited, but it is usually 0.5%.
  • the amount of the epoxy resin is less than 0.5%, the adhesion of the composition to a metal surface may tend to decrease.
  • the foam of the cured material of the composition tends to shrink when the composition is cured at a temperature of 180° C. or higher.
  • the amount of the latent curing agent exceeds 5%, the effect of the latent curing agent on the curing of the epoxy resin may saturate.
  • the lower limit of the amount of the latent curing agent may not be particularly limited, but it is usually 0.05%.
  • the amount of the latent curing agent is less than 0.05%, the epoxy resin may be insufficiently cured.
  • the amount of the crosslinking agent exceeds 5%, the adhesion of the composition tends to decrease, and such an amount of the crosslinking agent is excessive since the crosslinking degree of the unvulcanized rubber is already saturated at an amount of 5% or less of the crosslinking agent.
  • the lower limit of the amount of the crosslinking agent may not be particularly limited, but it is usually 0.01%.
  • the amount of the crosslinking agent is less than 0.01%, the formation of a film may be insufficient, and a sufficient expansion ratio may not be attained.
  • the expansion ratio may be insufficient.
  • the amount of the blowing agent exceeds 10%, open cells tend to form or the composition may insufficiently be adhered to a substrate because of excessive blowing.
  • the automatic injecting type paste form heat-curable damming injection composition of the present invention (hereinafter simply referred to as “paste damming injection composition”) has a preferred formulation described below, and a viscosity of 30 to 500 Pa ⁇ s (at 20° C. and a shear rate of 430 sec ⁇ 1 ), its gelation starting temperature is 90° C. or less, and it has a viscosity after gelation of 100,000 Pa ⁇ s (at a gelation temperature).
  • Paste Damming Injection Composition Partially crosslinked rubber 1-15%, preferably 4-10% Plasticizer 20-40%, preferable 25-35% Thermoplastic resin 5-20%, preferably 8-15% Epoxy resin 10% or less, preferably 0.5-10%, more preferably 1-6% Latent curing agent 5% or less, preferably 0.1-5%, more preferably 1-3% Additive(s) 40-60%, preferably 45-55%
  • the amount of the partially crosslinked rubber is less than 1%, the anti-stringy property and also the maintenance of a shape may be insufficient.
  • the amount of the partially crosslinked rubber exceeds 15%, a discharge property of the composition tends to deteriorate.
  • the amount of the plasticizer is less than 20%, the production of the composition is difficult, and a discharge property of the composition is insufficient.
  • amount of the plasticizer exceeds 40%, the composition may sag so that the shape of the applied composition may not be maintained.
  • the viscosity of the damming injection composition during gelation tends to decrease so that the damming injection composition cannot resist against the blowing pressure of the foam.
  • the amount of the thermoplastic resin is less than 5%, the viscosity of the damming injection composition during gelation is low so that the damming injection composition cannot resist against the pressure of the sagging paste injection composition and thus the closed section of the automobile body part is insufficiently filled.
  • the amount of the thermoplastic resin exceeds 20%, the viscosity stability of the damming injection composition tends to greatly deteriorate so that the discharge property may be adversely affected.
  • the amount of the epoxy resin exceeds 10%, the viscosity stability of the composition tends to decrease.
  • the lower limit of the amount of the epoxy resin may not be particularly limited, but it is usually 0.5%.
  • the amount of the epoxy resin is less than 0.5%, the adhesion of the composition to a metal surface may decrease.
  • the amount of the latent curing agent exceeds 5%, the effect of the latent curing agent on the curing of the epoxy resin may not be further improved, while the viscosity stability of the damming injectgion composition tends to deteriorate.
  • the lower limit of the amount of the latent curing agent may not be particularly limited, but it is usually 0.1%. When the amount of the latent curing agent is less than 0.1%, the epoxy resin may be insufficiently cured.
  • the injecting and soundproofing method of the present invention may be carried out in the following procedures:
  • the paste injection composition of the present invention is automatically applied to a respective surface site of the automobile body part preferably with a robot system in the form of a single or multiple beads (or bands).
  • An applied amount of the paste injection composition may be determined depending on the cross sectional area of the closed section, and is usually from 0.1 to 10 cc per square centimeter (cm 2 ) of the cross sectional area.
  • the paste damming injection composition is applied in adjacent to the paste injection composition, or at a distance from the paste injection composition, for example, a distance of 0 to 100 mm, in an amount of 0.05 to 5 cc per square centimeter (cm 2 ) of the cross sectional area.
  • the paste damming injection composition is also preferably automatically applied.
  • the automobile body parts are assembled by spot welding, and then passed through the pretreatment steps and the electrodeposition coating step.
  • the paste injection composition and the paste damming injection composition are uncured, they are have good resistance to shower and do not fly about, dissolve or drop off in the phosphate treating liquid or the electrodeposition coating liquid, since they have good shape maintenance properties.
  • the assembled automobile body parts are heated under the baking conditions in the electrodeposition oven in the electrodeposition coating step usually at a temperature of 140 to 220° C. for 10 to 60 minutes.
  • the paste damming injection composition begins to gel at a temperature lower than 100° C. at which the blowing of the paste injection composition begins, and the gelled damming injection composition has a very high viscosity of, for example, 100,000 Pa ⁇ s or larger. Therefore, the gelled damming injection composition can prevent the sagging of the paste injection composition, if the latter sags. As shown in FIG. 1 ( 2 ), the paste injection composition forms a foam having a good expansion ratio of 3 to 30 (an insulation wall).
  • the paste injection composition and the paste damming injection compositions were subjected to a gelation behavior analysis (paste damming injection compositions) by dynamic viscoelasticity measurement, or a foaming behavior analysis (paste injection composition) by differential scanning calorimetry. The results are shown in FIG. 4 .
  • the paste injection composition started to foam around 120° C., while the gelation behaviors of the paste damming injection compositions of Example 1 and Comparative Examples 1 and 2 were as follows:
  • the gelation of the paste damming injection composition of Example 1 finished earlier (gelation start temperature: 77.8° C., gelation finish temperature: 86.9° C.). Furthermore, the paste damming injection composition of Example 1 had a very high viscosity (125,000 Pa ⁇ s) at the finish of gelation. Therefore, the gelled material of the paste damming injection composition of Example 1 was hardly deformed by the foaming pressure of the paste injection composition so that the former could effectively dam the flow of the latter.
  • the paste damming injection composition of Comparative Example 1 had substantially the same gelation start temperature (81.9° C.) and the gelation finish temperature (87° C.) as those of the paste damming injection composition of Example 1, it had the lower viscosity at the finish of gelation (29,700 Pa ⁇ s). Accordingly, the gelled material of the paste damming injection composition of Comparative Example 1 was deformed by the foaming pressure of the paste injection composition so that the former could not dam the flow of the latter.
  • the paste damming injection composition of Comparative Example 2 had a sufficiently high viscosity (101,000 Pa ⁇ s) at the finish of gelation, it had a high gelation start temperature (111.9° C.) and a high gelation finish temperature (133° C.). Thus, the gelation could not be completed before the start of foaming of the paste injection composition and the paste damming injection composition of Comparative Example 2 was deformed by the foaming pressure of the paste injection composition.
  • a paste injection composition of the present invention when used, a closed section of an automobile body part, which has a large cross sectional area and thus cannot be completely filled with a conventional paste form heat-blowing injection composition, but a paste injection composition of the present invention, can be completely filled since the sagging of the paste injection composition is effectively prevented during heating and foaming of the paste injection composition by the use of the paste damming injection composition.

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  • Structural Engineering (AREA)
  • Architecture (AREA)
  • General Chemical & Material Sciences (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Body Structure For Vehicles (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
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US20080281007A1 (en) * 2005-11-10 2008-11-13 Wacker Chemie Ag Foamable Composition for Production of Foamed Plastics
US20100159225A1 (en) * 2008-12-22 2010-06-24 The Gates Corporation Method for making composite article with expandable elastomer in compression
US20110288201A1 (en) * 2009-02-09 2011-11-24 Huntsman International Llc Powder coating composition
US20130280451A1 (en) * 2010-12-27 2013-10-24 Sunstar Engineering Inc. Paste-like thermally expandable filler
US20180037708A1 (en) * 2016-08-08 2018-02-08 Sika Technology Ag Pumpable and thermally expandable filler compositions
US11920028B2 (en) 2021-05-25 2024-03-05 Sunstar Engineering Inc. Curable composition and method for producing curable composition
US11975762B2 (en) 2019-02-22 2024-05-07 Jfe Steel Corporation Crashworthiness energy absorption parts for automotive

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KR100826834B1 (ko) 2008-02-04 2008-05-02 김영동 소음방지 조성물 제조방법 및 이를 이용한 소음방지 바닥시공방법
JP6566827B2 (ja) * 2015-10-06 2019-08-28 トヨタ自動車九州株式会社 発泡充填剤の塗布方法、発泡充填剤の塗布装置、及び発泡充填剤
JP7026088B2 (ja) * 2019-02-22 2022-02-25 Ｊｆｅスチール株式会社 自動車用衝突エネルギー吸収部品
JP7231495B2 (ja) * 2019-06-17 2023-03-01 株式会社ミツバ ブレードラバー、ワイパブレードおよびブレードラバーの製造方法
JP7212648B2 (ja) * 2020-06-17 2023-01-25 Ｊｆｅスチール株式会社 自動車用衝突エネルギー吸収部品
WO2022249282A1 (ja) * 2021-05-25 2022-12-01 サンスター技研株式会社 硬化性組成物及び硬化性組成物の製造方法
WO2024095701A1 (ja) 2022-11-01 2024-05-10 サンスター技研株式会社 一液型硬化性組成物

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US5804608A (en) * 1995-01-21 1998-09-08 Mitsubishi Jidosha Kogyo Kabushiki Kaisha Heat-foamable filling reinforcement and reinforced closed-section structural-member making use of the same

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20080281007A1 (en) * 2005-11-10 2008-11-13 Wacker Chemie Ag Foamable Composition for Production of Foamed Plastics
US20100159225A1 (en) * 2008-12-22 2010-06-24 The Gates Corporation Method for making composite article with expandable elastomer in compression
WO2010074727A3 (en) * 2008-12-22 2011-01-20 The Gates Corporation Method of making composite article with expandable elastomer in compression
US8246872B2 (en) 2008-12-22 2012-08-21 The Gates Corporation Method for making composite article with expandable elastomer in compression
US9731438B2 (en) 2008-12-22 2017-08-15 Gates Corporation Composite article with expandable elastomer in compression
US20110288201A1 (en) * 2009-02-09 2011-11-24 Huntsman International Llc Powder coating composition
US8912254B2 (en) * 2009-02-09 2014-12-16 Huntsman International Llc Powder coating composition
US20130280451A1 (en) * 2010-12-27 2013-10-24 Sunstar Engineering Inc. Paste-like thermally expandable filler
US20180037708A1 (en) * 2016-08-08 2018-02-08 Sika Technology Ag Pumpable and thermally expandable filler compositions
US10836881B2 (en) * 2016-08-08 2020-11-17 Sika Technology Ag Pumpable and thermally expandable filler compositions
US11975762B2 (en) 2019-02-22 2024-05-07 Jfe Steel Corporation Crashworthiness energy absorption parts for automotive
US11920028B2 (en) 2021-05-25 2024-03-05 Sunstar Engineering Inc. Curable composition and method for producing curable composition

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EP1632523B1 (de) 2012-07-18
JP4675235B2 (ja) 2011-04-20
CA2526512A1 (en) 2004-12-16
CA2526512C (en) 2013-01-22
JPWO2004108807A1 (ja) 2006-07-20
CN1802406A (zh) 2006-07-12
WO2004108807A1 (ja) 2004-12-16
US20100187116A1 (en) 2010-07-29
CN1802406B (zh) 2010-09-01
US9045161B2 (en) 2015-06-02
EP1632523A4 (de) 2008-02-27
KR20060016795A (ko) 2006-02-22
EP1632523A1 (de) 2006-03-08
ES2388526T3 (es) 2012-10-16
KR101052659B1 (ko) 2011-07-28

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