Method for applying flowable materials Number:7,043,815 from the United States Patent and Trademark Office (PTO) owispatent Methods and apparatuses are disclosed for applying melt flowable materials to components of articles of manufacture. The methods and apparatuses disclosed herein are concerned with formation of appropriate flowable materials, control over the manner in which the flowable materials are applied, treatment of the components prior to application of the flowable materials and the like. Moreover, the apparatuses and methods may be particularly suited for applying flowable materials to surfaces and components found in automotive, aerospace, and marine vehicles.<H materials, flowable, Method, for, appl, 7043815.html, Patent, pto, 7043815

Title: Method for applying flowable materials

Abstract: Methods and apparatuses are disclosed for applying melt flowable materials to components of articles of manufacture. The methods and apparatuses disclosed herein are concerned with formation of appropriate flowable materials, control over the manner in which the flowable materials are applied, treatment of the components prior to application of the flowable materials and the like. Moreover, the apparatuses and methods may be particularly suited for applying flowable materials to surfaces and components found in automotive, aerospace, and marine vehicles.

Patent Number: 7,043,815 Issued on 05/16/2006 to Lande, et al.

Inventors: Lande; Maurice (Bloomfield Hills, MI); Czaplicki; Michael J. (Rochester, MI)
Assignee: L & L Products, Inc. (Romeo, MI)

Appl. No.: 342025

Filed: January 14, 2003

Current U.S. Class: 29/430 ; 29/460; 29/527.1; 29/792; 425/149; 425/162; 425/192R; 427/318; 427/409; 901/31; 901/41

Current International Class: B29C 47/92 (20060101)

Field of Search: 29/458,527.1,527.2,709,714,460,430,783,785,791,792 427/409,314,318 425/192R,145,162,170 901/1,31,41,43

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Primary Examiner: Cozart; Jermie E.
Attorney, Agent or Firm: Dobrusin & Thennisch PC

Parent Case Text

CLAIM OF BENEFIT OF FILING DATE

The present application claims the benefit of the filing date of U.S. Provisional Patent Application Ser. No. 60/351,967 (filed Jan. 25, 2002), hereby incorporated by reference.

Claims

What is claimed is:

1. A method for applying a flowable material to a plurality of components for one or more automotive vehicles the method comprising: providing a first surface of the plurality of components; providing a dispenser capable of applying the flowable material to the plurality of components; providing an automated apparatus for moving the plurality of components during application of the flowable material to the plurality of components, the automated apparatus being selected from a carousel or a robot arm; applying the flowable material with the dispenser upon the first surface of the plurality of components in a slightly flowable state such that the flowable material wets and adheres to the first surface; and transporting the plurality of components to or within an assembly plant; assembling the plurality of components to the one or more automotive vehicles prior to painting the body of the one or more automotive vehicles; and expanding the flowable material through the use of heat typically encountered in an e-coat or other automotive paint oven operation.

2. A method as in claim 1 wherein the first surface includes at least one contaminant material disposed thereon and the method further comprises treating the first surface of the component for removing the at least one contaminant material therefrom and the step of treating the first surface of the component includes applying a primer to the first surface, washing the first surface or exposing the surface of the component to energy from an energy source for removing the at least one contaminant material from the first; and wherein the step of treating the first surface includes exposing the surface of the component to energy from an energy source wherein the energy is selected from heat, plasma, light or near infrared light and the energy source is selected from a plasma generator, a laser, a flash lamp, a heat lamp or a NdYag laser; and wherein the step of applying the flowable material to the first surface occurs without pre-heating the first surface.

3. A method as in claim 1 wherein the flowable material is selected from an olefinic-polymer based flowable material, an ethylene-polymer based material or an epoxy based flowable material and the flowable material includes an ingredient selected from a solubilizing agent, a low compatibility component, a polar ingredient or an ingredient modified with an adhesion promoter.

4. A method as in claim 1 wherein the step of applying the flowable material upon the first surface includes extruding the flowable material as a bead and wherein the flowable material is substantially tack-free at temperatures near room temperature.

5. A method as in claim 4 wherein the component are a part of the automotive vehicle selected from a door beam, a closure panel, a trunk lid, a hood a roof bow, a fuel filler door, exterior trim or a vehicle pillar.

6. A method as in claim 5 wherein the flowable material has a base resin with a narrow molecular weight distribution.

7. A method as in claim 5 wherein the component are formed of a metal selected from steel, aluminum, or stamped metal.

8. A method as in claim 1 further comprising heating the surface of the component prior to applying the flowable material to the surface wherein the step of heating the surface includes exposing the surface to a lamp, exposing the surface to a blower, exposing the surface to a flame or combinations thereof.

9. A method as in claim 1 wherein the step of applying the flowable material includes extruding the flowable material with the dispenser, the dispenser including: i) a supply of the flowable material, the flowable material being provided as pellets in a container; ii) an extruder in communication with the supply of flowable material for receiving the pellets, the extruder capable of intermixing the pellets of flowable material into a viscoelastic state and dispensing the flowable material, the extruder including a rotatable screw for dispensing the flowable material; iii) a system for moving the extruder or the component during dispensing of the flowable material; and iv) a controller in communication with the extruder and the system wherein the controller employs closed loop control to control output of flowable material based upon a metering system that relates screw rotational speed to the output.

10. A method as in claim 9 wherein the controller is programmed to reverse a direction of rotation of the extruder screw for retracting the flowable material a short distance after an application of the flowable material to the component.

11. A method as in claim 9 wherein the controller is a programmable logic controller in communication with the extruder, the programmable logic controller programmed with a profile that relates an output rate of flowable material to a position angle of the extruder and a rotational speed of the extruder screw and wherein the programmable logic controller employs closed loop control in conjunction with the profile to set the output rate at a desired level.

12. A method as in claim 9 wherein the extruder includes a nozzle arrangement including an extrusion die through which material is extruded from the extruder to the component and wherein the extrusion die is attached to the extruder with a quick change attachment device selected from a quick nut and bolt fastener, a hydraulic quick connect fastener or a male/female quick connect fastener and further wherein the extrusion die include a plurality of openings for emitting a plurality of beads of flowable material.

13. A method as in claim 9 further comprising a screw bearing assembly associated with the extruder, the assembly have a first thrust bearing and a second thrust bearing, the first and second thrust bearings configured to act in opposite directions.

14. A method as in claim 9 wherein the extruder is configured to dispense the flowable material upon the components within a tolerance of less than 3 millimeters upon a surface of the components and the apparatus includes a source of vacuum pressure for moving pellets from the container to the extruder.

15. A method as in claim 1 wherein the automated apparatus is a carousel.

16. A method for applying a flowable material to a component of an article of manfacture, the method comprising: providing a first surface of the component; and extruding the flowable material upon the first surface in a slightly flowable state such that the flowable material wets and adheres to the first surfacem the flowable material being extruded with an automated apparatus, which includes: (i) a supply of the flowable material, the flowable material being provided as pellets in a container; (ii) an extruder in communication with the supply of flowable material for receiving the pellets, the extruder capable of intermixing the pellets of flowable

17. A method for applying a flowable material to a component of an article of manufacture, the method comprising: providing a first surface of the component; and extruding the flowable material upon the first surface in a slightly flowable state such that the flowable material wets and adheres to the first surface, the flowable material being extruded with an automated apparatus, which includes: i) a supply of the flowable material, the flowable material being provided as pellets in a container; ii) an extruder in communication with the supply of flowable material for receiving the pellets, the extruder capable of intermixing the pellets of flowable material into a viscoelastic state and dispensing the flowable material, the extruder including a rotatable screw for dispensing the flowable material wherein the extruder includes a nozzle arrangement including an extrusion die through which material is extruded from the extruder to the component and wherein the extruder die is attached to the extruder with a quick change attachment device selected from a quick nut and bolt fastener, a hydraulic quick connect fastener or a male/female quick connect fastener and further wherein the extrusion die includes a plurality of openings for emitting a plurality of beads of flowable material; iii) a system for moving the extrusion component during dispensing of the flowable material wherein the system includes a robot arm, a conveyor or a carousel for moving the component; and iv) a programmable logic controller in communication with the extruder and the system wherein the programmable logic controller is programmed with a profile that relates an output rate of flowable material to a position angle of the extruder and a rotational speed of the extruder screw and wherein the programmable logic controller employs closed loop control in conjunction with the profile to set the output rate at a desired level and wherein the controller is programmed to reverse a direction of rotation of the extruder screw for retracting the flowable material a short distance after an application of the flowable material to the component.

18. A method for applying a flowable material to a component for an automotive vehicle, the method comprising: providing a first surface of a plurality of components of an automotive vehicle, each of the plurality of components being formed of plastic and including a cavity, a gap or a seam at least partially defined by the first surface; providing a dispenser capable of applying the flowable material to the plurality of components, the dispenser including a metering system and the material being an adhesive sealant; providing an automated apparatus for moving the plurality of components during application of the flowable material to the plurality of components wherein the automated apparatus is a carousel and the plurality of components are mounted upon supports associated with the carousel; applying the flowable material with the dispenser as a bead to the cavity, gap or seam that is at least partially defined by the first surface of the plurality of components in a slightly flowable state such that the flowable material wets and adheres to the first surface wherein the flowable material is applied in metered amounts about the periphery of each of the plurality of components using the metering system; and transporting the component along with a plurality of other components to or within an assembly plant; assembling the component to the automotive vehicle prior to painting the body of the automotive vehicle; and expanding the flowable material through the use of heat typically encountered in an e-coat or other automotive paint oven operation.

19. A method as in claim 18 wherein a controller is in communication with the automated apparatus and the dispenser for assisting in controlling the movement of the plurality of components and the dispensing of the flowable material.

20. A method as in claim 19 wherein the plurality of components are formed of a molded or extruded plastic.

21. A method as in claim 20 wherein the flowable material has a narrow molecular weight distribution.

22. A method as in claim 21 wherein the flowable material is selected from an olefinic-polymer based flowable material, an ethylene-polymer based material or an epoxy based flowable material.

Description

TECHNICAL FIELD

The present invention generally relates to methods and apparatuses for applying flowable materials to articles of manufacture. More particularly, the present invention relates to methods and apparatuses for applying melt flowable materials such as adhesive materials, sealant materials, expandable materials, weldable materials, structural materials, paintable materials or the like to components of automotive vehicles.

BACKGROUND OF THE INVENTION

Sealants, adhesives and other flowable or moldable materials are often used on various components of a variety of articles of manufacture. Such flowable materials, for example, are applied to several components of an automotive vehicle for purposes such as increasing the structural integrity of the vehicle, sealing, attaching components of the vehicle together, or improving vehicle noise, vibration or harshness (NVH) characteristics.

Application of the flowable materials to the various components can create a variety of challenges. There may be challenges presented in forming flowable materials with desired properties. For instance, the flowable materials may need to be formed with chemical properties, physical properties or both, which are compatible with the components to which the flowable materials are applied thereby allowing the flowable materials to adhere or otherwise interact with the components. There may be further challenges presented in designing and manufacturing effective apparatuses for applying the flowable materials to different components. For instance, challenges may be presented for forming apparatuses that can properly control the rates of creation and the rates of output of the flowable materials. There may be still further challenges presented by the various design aspects of the components to which the flowable materials are applied. For instance, the geometry of the components, the processing of the components and other similar design aspects can present a myriad of challenges to application of the flowable materials.

A number of methods found in the prior art relate to so-called "pumpable" products that are fluidic materials applied to selected portions of a vehicle during the assembly process. Although these methods may be highly advantageous in some circumstances and applications, the use of pumpable materials and equipment often tend to create additional maintenance and clean-up requirements in the manufacturing facility as well as increased labor demand. Certain aspects of the present invention serve to eliminate the need for pumpable products and methods by providing a method, process, and apparatus for the extrusion-in-place or dispensing of flowable materials directly to a selected surface or location through improved extrusion techniques, which can be employed for applying a variety of thermoplastic and thermosettable materials.

Accordingly, the methods and apparatuses disclosed in the present invention overcome the drawbacks and disadvantages of the prior art by economically and effectively extruding or otherwise dispensing flowable materials to components of articles of manufacture.

SUMMARY OF THE INVENTION

The present invention broadly involves methods and apparatuses for applying flowable materials onto components of articles of manufacture. In particular preferred embodiments, the invention involves precisely extruding a highly viscous flowable material onto one or more predetermined locations of one or more components of an automotive vehicle.

The flowable materials being applied according to the present invention may be adhesive materials, sealant materials, expandable materials, structural materials, weldable materials, weld-through materials, paintable materials or other suitable flowable materials. In one highly preferred embodiment, the flowable materials may be treated or otherwise processed for the application of additional materials which facilitate and allow the formation of a class A painted surface finish, or other class of painted or treated surface, upon the flowable material. In other embodiments, the flowable materials may be electrically conductive, insulative, magnetic, transparent or possess another advantageous property along some or all of its length.

Preferably, the flowable materials are applied as one or more blends in a first physical state (e.g., unfoamed, having a particular sectional profile, uncured, or otherwise) and are thereafter exposed to a stimulus such as heat, a chemical or another suitable stimulus to induce or activate the flowable materials to transform (reversibly or irreversibly) to a second physical state (e.g., foamed, to a different sectional profile, cured or otherwise). Moreover, the flowable materials may intrinsically exhibit various desirable properties such as sound absorption, vibration absorption, corrosion resistance, adhesivity, sealing properties, strength, stiffness and the like which may enhance respective properties of components that receive the materials. Alternatively, the flowable materials when applied, produce a combination with the underlying component that is enhanced in one ore more relevant property.

The present invention is further characterized by the use of equipment and methods, such as improved extrusion methods, designs, and equipment, which apply material directly onto the receiving part to form an assembly that can be further handled and incorporated in the assembly process. It is contemplated that the materials to be utilized in the present invention will generally be flowable materials, such as thermoplastic or thermosettable materials, typically encountered in manufacturing operations, such as the manufacturing of automotive, aerospace, marine and other vehicles as well as appliances, motor driven devices, and articles of furniture.

One preferred apparatus of the present invention typically includes an applicator for reproducibly dispensing the flowable materials onto a surface. In one embodiment, the apparatus includes an extruder for dispensing the flowable material through a die. In other embodiments, the apparatus may include mechanisms for moving components relative to an applicator (e.g., a die) of the apparatus, mechanisms for moving the applicator relative to the components or a combination thereof. For example, the extrusion apparatus and mechanisms of the present invention may utilize at least one roller bearing capable of double action movement to push and roll the chosen material. More particularly, the present invention may include extrusion devices having at least one drive screw which interacts and responds to reaction force to attenuate consistency, set back, ramping, and control of response time. In this regard, the present invention may utilize a servo driven position controlled system to drive the screw of the extruder and control its operations and response time, which can be as low as about 0.1 second. In this aspect of the present invention, the servo driven position controlled system may further comprise a servo loop, which receives feedback from an encoder, a servo valve, which provides the position control, and computer software to facilitate communication of the servo system and direct the system to function to the preselected response time. In still other embodiments, the present invention may incorporate an apparatus for the precision control system for the dispensing and application of flowable materials.

Among the methods of the present invention are methods for forming the flowable materials, methods for applying the flowable materials, methods for treating the surfaces of the components to which the flowable materials are applied, and combinations of such methods.

The components that receive a flowable materials preferably provide a surface suitable for receipt of the flowable material. In one embodiment, the surface of a component is configured to include a structure for increasing surface area for receiving the flowable materials, such as a channel, a rib, or otherwise. In another embodiment, the surfaces of the components may be treated (e.g., pretreated, post-treated or otherwise) to enhance adhesion of the flowable materials to its application surface. According to another aspect of the invention, flowable materials are applied to components that were previously unsuitable for receiving the flowable materials because of the nature or properties of the flowable materials, the components or both.

BRIEF DESCRIPTION OF THE DRAWINGS

These, and further aspects or embodiments of the invention will be made clear or will be become apparent during the course of the following description of a preferred embodiment of the present invention. In the drawings, which form an integral part of the specification and are to be read in conjunction therewith, and in which like reference numerals are employed to designate identical parts in the various views:

FIG. 1 is a perspective view of an apparatus having an illustrative portable extruder shown mounted on the end of a robotic arm, depicting use of the apparatus to apply extruded materials to parts on an off-line basis according to one aspect of the present invention;

FIG. 2 is a sectional view of the portable extruder, taking along the line 2--2 in FIG. 1;

FIG. 3 is an operational diagrammatic view of the portable extruder shown in FIG. 1;

FIG. 4 is a view of the portable extruder of FIG. 1, but shown in relationship to an assembly line for manufacturing automobiles;

FIG. 5 is an enlarged, perspective view of a portion of a vehicle body and the extruder shown in FIG. 4;

FIG. 6 is a cross-sectional view taken along the line 6--6 in FIG. 5;

FIGS. 7a and 7b are views similar to FIG. 6 but showing a roof panel having been installed, and depicting the position of the extruded sealant bead respectively before and after expansion thereof;

FIG. 8 is a fragmentary, cross-sectional view of an alternate form of a nozzle for use with the extruder of FIG. 1;

FIG. 9 is a perspective view of an extruder according to the present invention, depicting an alternate form of a material supply system;

FIG. 10 is an enlarged, cross-sectional view of the batch hopper and supply feed tube of the system shown in FIG. 9, immediately after a batch has been dispensed;

FIG. 11 is a perspective view of an alternate form of the extruder of the present invention, shown in relationship to a conveyor line; and

FIG. 12 is a fragmentary rear view of the extruder of FIG. 11.

FIG. 13 is a block diagram of an automated system for tracking materials.

FIG. 14 is an overhead view of a system and apparatus for dispensing flowable materials onto panels of automotive vehicles.

FIG. 15 illustrates an exemplary movement system according to an aspect of the present invention.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

The present invention involves applying flowable material to various components of articles of manufacture such as automotive vehicles. The description of this invention first discusses the potential flowable materials that can be applied according to the methods and using the apparatuses of the invention. Thereafter, the methods and apparatuses that may be used for applying the flowable materials are discussed. Lastly, the components of the articles of manufacture that receive the flowable materials and the manner in which the flowable materials are applied are discussed.

Flowable Materials

The flowable materials of the present invention can be chosen from a variety of different materials. In certain cases, the flowable materials may be conventional, but may be applied according to novel methods or using novel apparatuses or both. In other cases, the flowable materials may be conventional or known, however, the component to which the flowable materials are applied may be novel. In still other embodiments, the flowable materials themselves may be novel. The discussion below is meant to introduce the flowable materials generally according to their chemical makeup and in terms of properties exhibited by the flowable materials, for assisting a person of skill in art in choosing a material, which typically needs to be selected or tailored for a specific desired application.

According to one embodiment of the invention, the flowable materials may be heat activated. A preferred heat activated material is an expandable or other flowable polymeric formulation or composition, and preferably one that is activated to foam, flow or otherwise change states when exposed to the heating operation of a typical automotive painting operation such as during a primer or paint drying step. A particularly preferred material is an active polymer formulated in pellet form with each pellet typically 1-20 mm in diameter and generally, but not necessarily, configured in a geometric or polygonal shape, such as a sphere, to facilitate the flow of such pellets through an applicator such as an extruder. One preferred material is formed of an olefinic polymer-based foam, and more particularly an ethylene based polymer. For example, without limitation, the polymeric foam may be based on ethylene copolymers or terpolymers that may possess an alpha-olefin. As a copolymer or terpolymer, the polymer is composed of two or three different monomers, i.e., small molecules with high chemical reactivity that are capable of linking up with similar molecules. Examples of particularly preferred polymers include ethylene vinyl acetate, EPDM, or a mixture thereof. Without limitation, other examples of preferred foam formulation that are commercially available include polymer-based material commercially available from L&L Products, Inc. of Romeo, Mich., under the designations as L-2105, L--2100, L-7005 or L-2018, L-7100, L-7101, L-7102, L-7700, L-2410, L-2411, L-2412, L-4201, L-4141, etc. and may comprise either open or closed cell polymeric base material. Such materials may exhibit properties including sound absorption, vibration absorption, sealing ability, corrosion resistance and the like.

The material may also be a heat-activated epoxy-based resin having foamable characteristics upon activation through the use of heat typically encountered in an e-coat or other automotive paint oven operation. As the expandable material is heated, it expands, cross-links, and structurally bonds to adjacent surfaces. An example of a preferred formulation is an epoxy-based material that may include polymer modifies such as an ethylene copolymer or terpolymer that is commercially available from L&L Products, Inc. of Romeo, Mich., under the designations that include L-5204, L-5206, L-5207, L-5208, L-5222 or combinations thereof. Such materials may exhibit properties including relatively high strength and stiffness, promote adhesion, rigidity, and impart other valuable physical and chemical characteristics and properties.

When acoustical damping properties are desired, it is contemplated that the present invention may utilize a foamable material formulated to assist in the reduction of vibration and noise after activation. In this regard, reinforced and vibrationally damped components can have increased stiffness which will reduce natural frequencies, that resonate through the automotive chassis thereby reducing transmission, blocking or absorbing noise through the use of the conjunctive acoustic product. By increasing the stiffness and rigidity of the components of a vehicle, the amplitude and frequency of the overall noise, vibration or both that occurs from the operation of the vehicle and is transmitted through the vehicle can be reduced.

In addition to the use of an acoustically damping material, the present invention could comprise the use of a combination of an acoustically damping material and a structurally reinforcing expandable material along different portions or zones of the member depending upon the requirements of the desired application. Use of acoustic expandable materials in conjunction with structural material may provide additional structural improvement but primarily would be incorporated to improve NVH characteristics.

A number of other suitable epoxy-based materials are known in the art and may also be used. One such foam preferably includes a polymeric base material, such as an ethylene-based polymer which, when compounded with appropriate ingredients (typically a blowing and curing agent), expands and cures in a reliable and predicable manner upon the application of heat or the occurrence of a particular ambient condition. From a chemical standpoint for a thermally activated material, the foam is usually initially processed as a flowable thermoplastic material before curing. It will cross-link upon curing, which makes the material resistant of further flow or change of final shape.

The flowable material can be formed of other materials (e.g., foams regarded in the art as structural foams) provided that the material selected is heat-activated or otherwise activated by an ambient condition (e.g. moisture, pressure, time or the like) and cures in a predictable and reliable manner under appropriate conditions for the selected application. One such material is the polymeric based resin disclosed in commonly owned, U.S. patent application Ser. No. 09/268,810 (filed Mar. 8, 1999) now U.S. Pat. No. 6,131,897, the teachings of which are incorporated herein by reference.

Some other possible materials include, but are not limited to, polyolefin materials, copolymers and terpolymers with at least one monomer type an alpha-olefin, phenol/formaldehyde materials, phenoxy materials, and polyurethane. See also, U.S. Pat. Nos. 5,266,133; 5,766,719; 5,755,486; 5,575,526; 5,932,680; and WO 00/27920 (PCT/US99/24795) (all of which are expressly incorporated by reference). Examples of suitable melt flow materials include, without limitation, formulations found in a commonly owned co-pending applications for a Paintable Seal System filed Aug. 7, 2000, and a Paintable Material filed Aug. 24, 2001, both hereby incorporated by reference. Still other materials and methods are disclosed in U.S. Application titled "Sound Absorption System for Automotive Vehicles", Ser. No. 09/631,211, filed Aug. 3, 2000 now U.S. Pat. No. 6,820,923.

In general, some desired characteristics of the resulting material include relatively low glass transition point, and good corrosion resistance properties in this manner, the material does not generally interfere with the materials systems employed by automobile manufacturers. Moreover, it will withstand the processing conditions typically encountered in the manufacture of a vehicle, such as the e-coat priming, cleaning and degreasing and other coating processes, as well as the painting operations encountered in final vehicle assembly.

In this regard, in applications where a heat activated, thermally expanding material is employed, a consideration involved with the selection and formulation of the material is the temperature at which a material reaction or expansion, and possibly curing, will take place. For instance, in most applications, it is undesirable for the material to be reactive at room temperature or otherwise at the ambient temperature in a production line environment since, in one embodiment, the material is extruded onto the intrusion device by a supplier and then shipped to the vehicle manufacturer as an integrated product. More typically, the material becomes reactive at higher processing temperatures, such as those encountered in an automobile assembly plant, when the material is processed along with the vehicle components at elevated temperatures or at higher applied energy levels, e.g., during e-coat preparation steps and other paint cycles. While temperatures encountered in an automobile e-coat operation may be in the range of about 145.degree. C. to about 210.degree. C. (about 300.degree. F. to 400.degree. F.), primer, filler and paint shop applications are commonly about 100.degree. C. (about 200.degree. F.) or higher. The material is thus operative throughout these ranges. If needed, blowing agent activators can be incorporated into the composition to cause expansion at different temperatures outside the above ranges.

Generally, suitable expandable flowable materials have a range of volumetric expansion from approximately 0 to over 2000 percent. The level of expansion of the vibration reduction material 20 may be increased to as high as 1500 percent or more in certain embodiments, the material may be hyper-expandable materials that expand more than 1500 percent and preferably over about 2000 percent. The material may be expandable to a degree (or otherwise situated on a surface) so that individual nodes remain separated from one another upon expansion, or they may contact one another (either leaving interstitial spaces or not).

In another embodiment, the material may be provided in an encapsulated or partially encapsulated form, which may comprise a pellet, which includes an expandable foamable material, encapsulated or partially encapsulated in an adhesive shell. An example of one such system is disclosed in commonly owned, U.S. application Ser. No. 09/524,298 ("Expandable Pre-Formed Plug") now U.S. Pat. No. 6,422,575, hereby incorporated by reference.

Moreover, the flowable material may include a melt-flowable material such as that disclosed in U.S. Pat. No. 6,030,701 (expressly incorporated by reference).

The choice of the flowable material used will be dictated by performance requirements and economics of the specific application end requirements. Generally speaking, automotive vehicle and other applications may utilize technology and processes such as those disclosed in U.S. Pat. Nos. 4,922,596, 4,978,562. 5,124,186, and 5,884,960 and commonly owned, U.S. application Ser. No. 09/502,686 filed Feb. 11, 2000 now U.S. Pat. No. 6,467,834 Ser. No. 09/524,961 filed Mar. 14, 2000, 60/223,667 filed Aug. 7, 2000, 60/255,126 filed Aug. 14, 2000, now U.S. Pat. No. 6,482,486 Ser. No. 09/676,443 filed Sep. 29, 2000, Ser. No. 09/676,335 filed Sep. 29, 2000 now U.S. Pat. No. 6,419,305 Ser. No. 09/676,725 filed Sep. 29, 2000, and particularly now U.S. Pat. No. 6,471,285 Ser. No. 09/459,756 filed Dec. 10, 1999, now U.S. Pat. No. 6,668,457, all of which are expressly incorporated by reference.

For application purposes, it is often desirable for the flowable materials of the present invention to be formulated such that the materials exhibit desired properties (e.g., tackiness or non-tackiness) at various different processing stages or temperature. Of course, it is contemplated that such properties or temperatures may be valuable depending upon the application of the flowable materials.

As discussed particularly for automotive operations, it is generally desirable for flowable materials of the present invention to activate and flow at temperatures experienced during paint cycles. Prior to activation, however, it is often preferable for the flowable materials to be exhibit solid and substantially non-tacky characteristics at temperatures near room temperature (e.g., between about 5.degree. C. and about 50.degree. C.), while exhibiting characteristics of slight flow and tackiness without activation at mid-level temperatures (e.g., between about 50.degree. C. and about 100.degree. C.). Advantageously, these characteristics allow the materials to be stored, transported and maintained in pellet form without substantial adhesion between the pellets. At the same time, the materials can be heated to mid-level temperatures to allow the materials to adhere to a substrate during application of the materials as further discussed below.

For forming a flowable material that exhibits such desired characteristics, a base resin with a narrow molecular weight distribution is preferably included in the material. The molecular weight distribution is preferably such that 70% of the polymers in the base resin are within 10,000 atomic mass units (amu) of each other, more preferably 80 percent of the polymers in the base resin are with 5000 amu of each other and even more preferably 90 percent of the polymers are within 1000 amu of each other. Preferably, the base resin comprises about 50 to about 100 weight percent of the material or of the polymeric constituents of the material and more preferably about 60 to about 90 weight percent of the material or of the polymeric constituents of the material.

It is also contemplated that the flowable materials may be formulated with one or more components, which assist in adhering the materials to a substrate upon application thereto. Typically, such components are added to achieve desirable interaction between the flowable materials and contaminants (e.g., oil and lubricants), which may be present upon a surface of a substrate to which the flowable material may be applied.

In one embodiment, the flowable material includes one or more solubilizing agents, which assist the flowable material in solubilizing contaminants on a substrate surface. Examples of such solubilizing agents include hydrocarbons (e.g, hydrocarbon process oils), pthalate plasticizers, liquid polyolefins or the like. Preferably, when used, such solubilizing agents are between about 1 and about 30 weight percent of the flowable material, more preferably between about 5 and about 20 weight percent of the flowable material.

In another embodiment, the flowable material includes one or more incompatible or low compatibility components, which can displace contaminants upon application of the flowable material to a substrate thereby assisting in adhesion of the flowable material to the substrate. Preferably, such components have relatively low molecular weights (e.g., less than 1000 g/mole) such that the components tend to migrate out the resin system of the flowable material. Examples of such components include polybutenes, polybutadienes, various waxes or the like. Preferably, when used, such low compatibility components are about 0.1 and about 30 weight percent of the flowable material, more preferably between about 2 and about 15 weight percent of the flowable material.

In another embodiment, the flowable material includes one or more polar components, which can aid in adhesion of the flowable material to the substrate. Preferably, such components have relatively low melting points (e.g., between about 50.degree. C. and about 100.degree. C.). Examples of such components include oxidized or otherwise functionalized waxes, epoxy resins or combinations thereof. Preferably, when used, such polar components are about 1 and about 30 weight percent of the flowable material, more preferably between about 2 and about 15 weight percent of the flowable material.

In still another embodiment, the flowable material includes one or more components such as waxes that are modified with an adhesion promoter such as an acid anhydride group. Preferably, when used, such modified components are about 1 and about 30 weight percent of the flowable material, more preferably between about 5 and about 20 weight percent of the flowable material.

In yet another embodiment, the flowable material includes a two-component system wherein a first component interacts with a second component to increase tack of the flowable material during application. For example, pellets of a relatively lower molecular weight material may be combined with pellets of a compatible higher molecular weight base polymer, which, upon mixing and elevation to a mid-range temperature, increase tack due to the compatibility of the two types of pellets. As another example, a small amount of pellets of one material may be combined with pellets formed of a second material wherein the first material has reactive functionality that is activated upon mixing with the second material for promoting adhesion.

Apparatuses for Application of Flowable Materials

An apparatus for applying flowable materials to components according to the present invention may be provided in a variety of configurations. The apparatus typically includes at least one applicator having an outlet through which the flowable materials are based. The applicator may comprise molding equipment such as compression