Improved constrained layer damping material and system for use with oil-based substrates

Abstract

An improved constraining layer vibration-damping patch for use directly on a substrate having a rust-preventive coating. The improved constraining layer vibration-damping patch includes a constraining layer, a damping layer, and a release liner. The improved constraining layer vibration-damping patch includes a damping layer having about 10 to about 15 weight percent of a butyl rubber composition, about 1 to about 5 weight percent of a tackifier, about 20 to about 25 weight percent of a plasticizer, about 60 to about 65 weight percent of a filler, and about 0.01 to 1 weight percent of a colorant, wherein the composition is substantially free of a curative, and the composition is free of an ethylene copolymer.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application is a PCT application claiming priority to U.S. Provisional Patent Application No. 63 / 118,546, filed November 25, 2020, the entire contents of which are incorporated herein by reference in their entirety.

[0002] The present invention relates to constrained layer damping systems and damping layer compositions, and more particularly to constrained layer vibration damping systems and damping layer compositions for use with oil-coated substrates. [Background technology]

[0003] Vibration damping systems are widely used in the automotive industry to reduce vibrations and noise generated by rolling transmissions, axle linkages, rolling bearings, and rolling tires. Vibration damping systems are typically applied to selected parts or areas of the automobile, such as the inner quarter panels, floor, roof, etc., to prevent vibrations from being transmitted into the automobile's passenger compartment.

[0004] A typical damping system includes a thermoplastic or rubber layer and a constraining layer that together suppress vibration. Several different damping systems are in use, including peel-bonded, spray-on full-panel damping, and constrained-layer damping. However, current systems have several problems, including proper location of the system, high installation costs, undesirable gaps between layers, and delamination of the system during assembly of the vehicle. The delamination problem is partially due to protective coatings applied to metal body parts. Currently, these overcome the delamination problem through timely and expensive cleaning of the metal surface. Therefore, there is a need in the art for vibration damping systems and materials that can be applied directly to protectively coated metal without losing adhesion or vibration damping. Summary of the Invention

[0005] An improved constraining layer vibration-damping patch is provided, comprising a constraining layer, a damping layer, and a release liner. In some embodiments, the improved constraining layer vibration-damping patch can further comprise a colorant.

[0006] The improved constrained layer vibration damping patch can include a damping layer including about 10 to about 15 weight percent of a butyl rubber composition, about 1 to 5 weight percent of a tackifier, 20 to 25 weight percent of a plasticizer, and 60 to 65 weight percent of a filler.

[0007] In some embodiments, the release liner can be removed and the remaining patch can be placed on a substrate, such as the interior surface of a vehicle door or body panel, thus forming a sandwich structure including a damping layer intermediate the constraining layer and the substrate. The substrate can include a protective coating, such as mineral oil, to prevent rust. The improved constraining layer vibration-damping patch can be used directly on the oily surface of the substrate. Although overlapping with other descriptions, various aspects of the present invention are described below, however, the present invention is not limited to the following. [1] 1. An improved constrained layer vibration damping patch comprising: Constraint layer, and a damping layer, the damping layer being composed of a butyl rubber composite, a tackifier, a plasticizer, and a filler composite; Improved constrained layer vibration damping patch. [2] 10. The improved constrained layer vibration damping patch of [1], further comprising a release liner. [3]

[0023] The improved constrained layer vibration damping patch of [1], further comprising a colorant. [4] The improved constrained layer vibration damping patch according to [2] or [3], wherein the butyl rubber composite is composed of a partially crosslinked butyl rubber and an isobutylene-isoprene butyl rubber composite. [5] [4] The improved constrained layer vibration damping patch of [4], wherein the isobutylene-isoprene butyl rubber composite is composed of isobutylene-isoprene butyl rubber and recycled isobutylene-isoprene butyl rubber. [6] Improved constrained layer vibration damping patch according to [1], [2], [3] or [4], wherein the tackifier is selected from rosin ester resins or aliphatic hydrocarbon resins. [7] 10. The improved constrained layer vibration damping patch of claim 1, wherein the plasticizer comprises at least one isobutylene-butene copolymer, a pure isobutene homopolymer, or a mixture thereof. [8] Improved constrained layer vibration damping patch according to [1], [2], [3], [4], [5] or [6], wherein the filler composite is composed of at least one functional filler and a general filler. [9] [7] The improved constrained layer vibration damping patch according to [7], wherein the at least one functional filler is composed of calcium oxide (CaO), talc, kaolin clay or mixtures thereof.

[10] The common filler is calcium carbonate (CaCO 3 ) and the improved constrained layer vibration damping patch described in [7].

[11] 10. The improved constrained layer vibration damping patch of claim 1, wherein the damping layer is substantially free of an enhancer.

[12] 10. The improved constrained layer vibration damping patch of claim 1, wherein the damping layer does not comprise an ethylene copolymer.

[13] 1. A vibration damping layer composition comprising: about 10 to about 15 weight percent of a butyl rubber composition; about 1 to about 5 weight percent of a tackifier; about 20 to about 25 weight percent plasticizer; about 60 to about 65 weight percent filler, and about 0.01 to 1 weight percent colorant; Substantially free of curatives and free of ethylene copolymers; Vibration damping layer composition.

[14] 1. An improved constrained layer vibration damping patch comprising: release liner, restraint layer, a damping layer including a first surface and a second surface; and the damping system includes a metal substrate to which the damping system is adhered; the damping layer includes a first surface and a second surface; the constraining layer is in physical communication with the first surface of the damping layer; the release liner is in physical communication with the second surface of the damping layer; the damping layer is adhered to the metal substrate such that when the release liner is removed from the second surface of the damping layer to expose the second surface of the damping layer, the second surface of the damping layer is in physical communication with the metal substrate and the damping layer is intermediate the constraining layer and the metal substrate; The damping layer comprises about 10 to about 15 wt % of a butyl rubber composite. Improved constrained layer vibration damping patch.

[15]

[14] The improved vibration damping patch according to

[14] , wherein the butyl rubber composite comprises a polyisobutylene butyl rubber and an isobutylene-isoprene butyl rubber composite.

[16] Improved vibration-damping patch according to

[14] or

[15] , wherein the metal substrate comprises steel having a protective coating to inhibit rust.

[17]

[16] The improved vibration-damping patch of

[16] , wherein the protective coating is comprised of about 60 weight percent to about 70 weight percent mineral oil.

[18] 10. The improved vibration damping patch of claim 14, wherein the damping patch exhibits a peel adhesion strength of between 9 N / cm and 13 N / cm when measured according to ISO 8510. [Brief explanation of the drawings]

[0008] [Figure 1] 1 is a schematic cross-sectional view of an embodiment of the improved constraining layer vibration damping patch of the present invention. [Figure 2] 1 is a schematic cross-sectional view of an improved constrained layer vibration damping patch adhered to a substrate. DETAILED DESCRIPTION OF THE INVENTION

[0009] The improved constrained layer vibration-damping patch of the present invention offers advantages over conventional vibration-damping materials used in the automotive industry. The improved vibration-damping patch eliminates the need to remove an oily protective layer that coats the automotive surface to which the improved vibration-damping patch is adhered, thus reducing manufacturing time and costs. The patch may also be applied to the surface of a substrate in fields other than automotive, and its use is not limited thereto.

[0010] The present invention will now be described in more detail by way of preferred embodiments with reference to the accompanying drawings.

[0011] Referring to Figure 1, shown in cross section is an improved vibration-damping patch of the present invention. As seen in Figure 1, the improved constraining layer vibration-damping patch can include a laminate sheet 10 including a constraining layer 11, a damping layer 12, and a release liner 13.

[0012] The constraining layer may be formed from a metallic, non-ferrous material such as aluminum foil, copper foil, stainless steel foil, cold-rolled steel, etc. If copper foil or cold-rolled steel foil is utilized, the material may be protected with a coating effective to prevent oxidation of the material. In other embodiments, the constraining layer may be constructed from a rigid, non-metallic material such as polypropylene, glass cloth (woven fabric made from glass fibers), lightweight foam, cardboard, wood, or any other rigid material.

[0013] The morphology of the constraining layer can affect the properties of the damping layer 12 or aid in the attenuation of various resonant frequencies, such as acoustic or vibration dissipation. The constraining layer can include smooth, dimpled, raised, or wave / corrugated surfaces.

[0014] The damping layer 12 can include a butyl rubber composite, a tackifier, a plasticizer, and a filler composite. The butyl rubber composite allows for flexibility and wetting of the damping layer during the manufacturing of the improved constrained layer vibration-damping patch. The flexibility and wetting properties of butyl rubber prevent the layer from disintegrating over its lifetime by, for example, preventing delamination from adhesives, shrinkage over time due to forming stresses during the manufacturing process, and adhesion to non-planar substrates. If the damping layer disintegrates, it will not be able to effectively dampen vibrations and acoustic resonances generated by the vehicle. In some embodiments, the butyl rubber composite can be composed of a partially crosslinked butyl rubber and an isobutylene-isoprene butyl rubber (IIR) composite.

[0015] The partially cross-linked butyl rubber component of the damping layer is commercially available as Polysar Butyls XL10000, XL68102, XL30102, and XL40302 (Polysar International Co.), Butyx 55, Butyx 63, Butyx 75, and Butyx 80 (Harmony Elastomers, LLC, Clifton, New Jersey, USA), and NexGen® XL-15, NexGen® XL-46, and NexGen® XL-63 (Alterra Holdings Co., Seymour, Indiana, USA). In some embodiments, the partially cross-linked butyl rubber may be comprised of NexGen® XL-15.

[0016] In some embodiments, the amount of partially cross-linked butyl rubber in the damping layer may comprise about 0.1 to about 5 weight percent (wt%) of the total weight of the damping layer composition. In some embodiments, the amount of partially cross-linked butyl rubber may comprise about 0.1 to about 0.5 wt%, about 0.5 to about 1 wt%, about 1 to about 1.5 wt%, about 1.5 to about 2 wt%, about 2 to about 2.5 wt%, about 2.5 to about 3 wt%, about 3 to about 3.5 wt%, about 3.5 to about 4 wt%, about 4 to about 4.5 wt%, and about 4.5 to about 5 wt% of the total weight of the damping layer composition. More specifically, the amount of partially crosslinked butyl rubber is 1 wt%, 1.1 wt%, 1.2 wt%, 1.3 wt%, 1.4 wt%, 1.5 wt%, 1.6 wt%, 1.7 wt%, 1.8 wt%, 1.9 wt%, or 2 wt% of the total weight of the damping layer composition. As used herein, the term "about" when describing a value or parameter includes the stated amount ±10%. In some embodiments, the term "about" includes the stated amount ±5%. In yet other embodiments, the term "about" includes the stated amount ±1%.

[0017] The IIR butyl rubber composite of the damping layer is composed of commercially available non-halogenated IIR butyl rubber and recycled IIR butyl rubber. Suitable commercially available non-halogenated IIR butyl rubbers include X-Butyl® RB100, X-Butyl® RB301, and X-Butyl® RB402 (Arlanxeo Co., Maastricht, Netherlands), Butyl 065, Butyl 077, Butyl 165, Butyl 268, Butyl 365, and Exxpro 96-1 (ExxonMobil Chemical). In some embodiments, the IIR butyl rubber can be X-Butyl® RB301. The recycled butyl rubber is a synthetic butyl rubber and is commercially available from Milin Environmental, Inc. (Simcoe, ON, Canada). In some embodiments, the recycled IIR butyl rubber can be about 1 to about 5 wt % of the total weight of the damping layer composition. In some embodiments, the recycled IIR butyl rubber can be synthetic butyl rubber. In some embodiments, the ratio of recycled IIR butyl rubber to IIR butyl rubber can be from about 1:4 to about 1:6.

[0018] In some embodiments, the IIR butyl rubber component of the butyl rubber composite can be in an amount of about 5 to about 10 wt% of the total weight of the damping layer composition. In some embodiments, the amount of the IIR butyl rubber component of the butyl rubber composite can be about 5 to about 5.5 wt%, about 5.5 to about 6 wt%, about 6 to about 6.5 wt%, about 6.5 to about 7 wt%, about 7 to about 7.5 wt%, about 7.5 to about 8 wt%, about 8 to about 8.5 wt%, about 8.5 to about 9 wt%, about 9 to about 9.5 wt%, about 9.5 to about 10 wt%, or any amount encompassed by the above ranges. Of particular interest are amounts of 7.5 wt%, about 7.6 wt%, about 7.7 wt%, about 7.8 wt%, about 7.9 wt%, and about 8 wt%.

[0019] In some embodiments, the recycled IIR butyl rubber component of the butyl rubber composite can be in an amount of about 1 to about 5 wt% of the total weight of the damping layer composition. In some embodiments, the recycled IIR butyl rubber component of the butyl rubber composite can be in an amount of about 1 to about 1.5 wt%, about 1.5 to about 2 wt%, about 2 to about 2.5 wt%, about 2.5 to about 3 wt%, about 3 to about 3.5 wt%, about 3.5 to about 4 wt%, about 4 to about 4.5 wt%, about 4.5 to about 5 wt%, or any amount bounded by the above ranges. Of particular interest are amounts of 1.3 wt%, 1.5 wt%, 1.7 wt%, 1.9 wt%, and 2 wt% of the total weight of the damping layer composition.

[0020] The tackifier for the damping layer may be comprised of commercially available rosin esters, aliphatic hydrocarbon resins, or mixtures thereof. The tackifier is used to provide flexibility and high initial adhesion to the damping layer composition. The tackifier is preferably present in an amount of about 2 to about 6 wt% of the total weight of the damping layer composition. In some embodiments, preferred amounts of tackifier may be about 2 to about 2.5 wt%, about 2.5 to about 3 wt%, about 3 to about 3.5 wt%, about 3.5 to about 4 wt%, about 4 to about 4.5 wt%, about 4.5 to about 5 wt%, about 5 to about 5.5 wt%, about 5.5 to about 6 wt%, or any amount bounded by the above ranges. In some embodiments, the amount of tackifier is preferably about 2.9 wt%, about 4 wt%, about 4.3 wt%, or about 6 wt%.

[0021] Suitable commercially available rosin ester resins include, but are not limited to, Trecos R86, Trecos R98, Trecos R100 (Teckrez, Inc., Jacksonville, FL, USA), Foral 85, Foral 105, Hercolyn (Hercules Powder Co., Wilmington, DE, USA), or mixtures thereof. In some embodiments, the tackifier can be Trecos R98 rosin ester.

[0022] Suitable commercially available aliphatic hydrocarbon resins include, but are not limited to, Escorez 1102, Escorez 1304, Escorez 1315 (ExxonMobil Chemical), Nevtec 10, Nevtec 80, Nevtec 100 (Neville Chemical Co., Pittsburg, PA, USA), Wingtack 10, Wingtack 95, Wingtack Plus (Goodyear Tire & Rubber Co., Akron, OH, USA), Piccotac 100, Piccotac B, Piccotac 95, Piccotac 115 (Hercules Powder Co.), or mixtures thereof. In some embodiments, the tackifier can be Wingtack 95 aliphatic hydrocarbon resin.

[0023] Plasticizers in the damping layer are used to impart flexibility, improve initial adhesion, and modify the viscosity of the damping layer. Plasticizers suitable for use with butyl rubber composites may include, but are not limited to, polybutene plasticizers such as Indopol® H100, Indopol® H300, Indopol® H1200, Indopol® H1500, Indopol® H1900, Indopol® H2100 (INEOS Oligomers, Alvin, TX, USA), Parapol 700, Parapol 950, Parapol 1300, Parapol 2100 (ExxonMobil Chemicals), Opanol B10, Opanol B12, Opanol B15 (BASF Chemical Co., Ludwigshafen, Germany), or mixtures thereof. Any other plasticizer or combination of plasticizers may be used.

[0024] One or more plasticizers can be used in the damping layer in an amount of about 20 to about 25 wt% of the total weight of the damping layer composition. In some embodiments, preferred amounts of plasticizer can be about 20 to about 21 wt%, about 21 to about 22 wt%, about 22 to about 23 wt%, about 23 to about 24 wt%, about 24 to about 25 wt%, or any amount bounded by the above ranges. Some preferred amounts of plasticizer are 21.3 wt%, 21.7 wt%, 22.1 wt%, 22.2 wt%, and 22.4 wt%.

[0025] The filler composite of the damping layer can be composed of general fillers, functional fillers, or mixtures thereof. Fillers can include organic or inorganic materials, such as, but not limited to, calcium carbonate, talc, quicklime, kaolin clay, silica, mica, or other mineral fillers known in the art. In some embodiments, the general filler can include calcium carbonate. An example of a commercially available calcium carbonate is Hubercarb Q325 (Huber Engineered Materials, Atlanta, GA, USA). Examples of commercially available functional fillers include, but are not limited to, HC-75 clay (Akrochem Co., Akron, OH, USA), Silverline 303 talc (IMCD, Westlake, OH, USA), Microcal OF200 quicklime (Mississippi Lime Co., St. Louis, MO, USA), or mixtures thereof. The filler composite can comprise a mixture of conventional fillers and functional fillers in an amount of about 60 wt% to about 65 wt% of the total weight of the damping layer composition, preferably about 62 to about 62.5 wt%, about 62.5 to about 63 wt%, about 63 to about 63.5 wt%, about 63.5 to about 64 wt%, about 64 to about 64.5 wt%, about 64.5 to about 65 wt%, or any amount bounded by these ranges.

[0026] In some embodiments, the improved constraining layer vibration-damping patch can further include a colorant. Non-limiting examples of colorants include N650 carbon black (The Cary Co., Addison, IL, USA), B22237 (Spartech LLC, Clayton, MO, USA), or other colorants not mentioned. The colorant or mixture of colorants may be used in an amount of 0.1 to 1 wt % of the total weight of the damping layer composition.

[0027] In some embodiments, the improved constraining layer vibration-damping patch can further include a release liner. The release liner is not particularly limited, and one skilled in the art can select a release liner from those known in the art for structural support purposes. In some embodiments, the release liner can be composed of a nonwoven material, a woven material, or a woven substrate. Examples of woven substrates include, but are not limited to, silica (glass), aramid, carbon fiber, metal oxides, minerals, ceramics, or other synthetic man-made fibers. Some non-limiting examples of nonwoven materials include cellulose, rayon, polyamide fluoride (PVDF), polyethylene (PE), polyethylene terephthalate (PET), polyether ketone (PEEK), and / or mixtures thereof. In some embodiments, the backing layer can be composed of polyethylene terephthalate.

[0028] Some embodiments include a vibration dampening patch composition comprising about 10-15 wt% of a butyl rubber composition, about 1-5 wt% of a tackifier, about 20-25 wt% of a plasticizer, about 60-65 wt% of a filler, and about 0.1-1 wt% of a colorant.

[0029] In some embodiments, the improved constraining layer vibration-damping patch can include a release liner, a constraining layer, and a damping layer. In some embodiments, the improved vibration-damping patch can include a metal substrate to which the patch is adhered. In some embodiments, the damping layer includes a first surface and a second surface, the constraining layer being in physical communication with the first surface of the damping layer, and the release liner being in physical communication with the second surface of the damping layer. The damping layer of the improved constraining layer vibration-damping patch can include a butyl rubber composite including polyisobutylene butyl rubber and isobutylene-isoprene butyl rubber. In some embodiments, the release liner is removed from the second surface of the damping layer to expose the second surface of the damping layer, and the damping layer is then adhered to the metal substrate such that the second surface of the damping layer is in physical communication with the metal substrate, resulting in the damping layer being intermediate the constraining layer and the metal substrate. In some embodiments, the damping layer can be comprised of approximately 10-15 wt % of the butyl rubber composite. The metal substrate can be coated with a protective coating to inhibit rust.

[0030] The protective coating can be comprised of approximately 60 to 70 percent mineral oil. The protective coating can be, for example, Ferrocote® 61MAL HCl (Quaker Chemical Co., Conshohocken, PA, USA). In some embodiments, the improved constrained layer vibration damping patch can exhibit a peel adhesion strength of between 9 and approximately 13 N / cm, measured according to the ISO 8510 protocol.

[0031] Generally, the damping layer of the present disclosure can be prepared by blending the partially crosslinked butyl rubber and isobutylene-isoprene butyl rubber composite together with a tackifier, plasticizer, and filler, and mixing the blend at 90°C to 140°C for about 45 to 120 minutes until the mixture reaches the maximum amperage for batch pull-up (the maximum amperage is the peak value of the mixer during mixing, which is 150 amperes).

[0032] The resulting damping layer 12 may be extruded between a constraining layer 11 and a release liner 13, as shown in Figure 1, resulting in the improved constraining layer vibration-damping patch of the present invention. In some embodiments, the release liner can be removed and the remaining patch can be placed on a substrate 24, such as the interior surface of a vehicle door or body panel, thus forming a sandwich structure including a damping layer 22 intermediate a constraining layer 21 and a substrate 24, as shown in Figure 2.

[0033] Unless otherwise indicated, all numbers expressing quantities of ingredients, properties such as molecular weight, reaction conditions, and the like used in the specification and embodiments should be understood to be modified in all instances by the term "about." Accordingly, unless indicated to the contrary, the numerical parameters set forth in the specification and accompanying embodiments are approximations that may vary depending, at least, on the desired properties sought to be obtained and are not intended to limit the application of the doctrine of equivalents. Within the scope of the embodiments, each numerical parameter should, at least, be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0034] For the disclosed processes and / or methods, the functions performed in the processes and methods may be implemented in differing order, as may be indicated by the context. Further, the outlined steps and operations are provided only as examples, and some of the steps and operations may be optional, combined into fewer steps and operations, or expanded into additional steps and operations.

[0035] The present disclosure may show different components contained within or connected to different other components. Such illustrated structures are merely examples, and many other structures may be implemented that achieve the same or similar functionality.

[0036] The terms used in this disclosure and the accompanying embodiments (e.g., the body of the accompanying embodiments) are generally intended as "non-limiting" terms (e.g., the term "including" should be interpreted as "including, but not limited to," the term "having" should be interpreted as "having at least," and the term "includes" should be interpreted as "including, but not limited to"). Also, when a specific number of elements is introduced, this may be interpreted to mean at least the recited number, as may be indicated by context (e.g., a plain recitation of "two enumerations" without other modifiers means at least two enumerations of two or more enumerations). As used in this disclosure, any disjunctive word and / or phrase presenting two or more alternative terms should be understood to contemplate the possibility of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" is understood to include the possibilities of "A or B" or "A and B."

[0037] As used in the context of describing the present disclosure (particularly in the context of the embodiments below), the terms "a," "an," "the," and similar referents should be construed to encompass both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The use of any and all examples or related language (e.g., "etc.") provided herein is intended merely to better clarify the disclosure and does not limit the scope of any embodiment. No language in the specification should be construed as indicating any non-embodied element essential to the practice of the disclosure.

[0038] Groupings of alternative elements or embodiments disclosed herein are not to be construed as limiting. Each group member may be referenced and embodied individually or in any combination with other members of the group or other elements found herein. It is anticipated that one or more members of a group may be included in, or deleted from, a group for reasons of convenience and / or patentability. When such inclusion or deletion occurs, the specification is deemed to include the modified group and, therefore, fulfills the description of all Markush groups used in the accompanying embodiments.

[0039] Certain embodiments have been described herein, including the best mode known to the inventors for carrying out the present disclosure. Of course, variations on these described embodiments will become apparent to those skilled in the art upon reading the foregoing description. The inventors anticipate that those skilled in the art will employ such variations as appropriate, and the inventors intend for the present disclosure to be practiced otherwise than as specifically described herein. Accordingly, the embodiments include all modifications and equivalents of the subject matter recited in the embodiments as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is contemplated unless otherwise indicated herein or clearly contradicted by context. Finally, it should be understood that the embodiments disclosed herein are illustrative of the principles of the embodiments. Other modifications that may be employed are within the scope of the embodiments. Thus, by way of example, and not of limitation, alternative embodiments may be utilized in accordance with the teachings herein. Accordingly, the embodiments are not limited to those precisely shown and described. [Example]

[0040] The following table of examples further illustrates various aspects of the present invention. In the following examples, all compositional data is given as the weight percent of the particular component based on the total weight of the damping layer composition. Compositions according to the following examples were prepared and their physical properties were measured, as shown in the data below.

[0041] Example 1: Comparative example (CE): The comparative damping layer formulation and its components can be found in Table 1 below. Table 1. [Table 1]

[0042] Example 2: CLDP-1 An exemplary CLDP-1 damping layer formulation and its components can be found in Table 2 below. Table 2 [Table 2]

[0043] Example 3: CLDP-2 An exemplary CLDP-2 damping layer formulation and its components can be found in Table 3 below. Table 3 [Table 3]

[0044] Example 4: CLDP-3 An exemplary CLDP-3 damping layer formulation and its components can be found in Table 4 below. Table 4 [Table 4]

[0045] Example 5: CLDP-4 An exemplary CLDP-4 damping layer formulation and its components can be found in Table 5 below. Table 5 [Table 5]

[0046] Example 6: CLDP-5 An exemplary CLDP-5 damping layer formulation and its components can be found in Table 6 below. Table 6 [Table 6]

[0047] Experiment 7: Peel adhesion strength test ISO 8510 Part 2 provides specific guidelines for peel adhesion testing. To prepare for such testing, vibration-damping patch specimens are cut into rectangular strips 1 inch wide and 13 inches long (this length is sufficient to bend the strip for a 180-degree peel). Because this vibration-damping patch invention is manufactured by a mass production-scale process, the performance of the strip specimens is adequately representative of such designs. Strip specimens should avoid significant defects.

[0048] The metal substrates used in this evaluation can include cold-rolled steel, hot-dip galvanized steel, or electrogalvanized steel. They are cut into rectangles measuring 2 inches wide and 7 inches long. Before use, the substrate surface must be thoroughly cleaned of any chemicals or contaminants. Isopropanol is effective for cleaning. After cleaning and drying, a specific protective lubricant is applied to the substrate by syringe and spread evenly over the entire area. In some embodiments, a lubricant containing 60-70% mineral oil can be used to provide a protective coating. Particular care must be taken to distribute the lubricant, as localized concentrations of the lubricant on the substrate surface can create weak spots for the strip sample to bond with the substrate. Furthermore, the substrate must be weighed before and after applying the lubricant so that the amount of lubricant on the substrate can be determined and recorded. After applying the lubricant, the now-oily substrate should be allowed to rest in a horizontal position for at least one hour before applying the strip sample.

[0049] Half the length of the strip sample is applied onto an oily, resting steel substrate. This is called the "peel assembly." The other half of the strip sample is bent for a 180-degree peel. A specified weight roller is used to roll over this assembly at a specified speed and with a specified cycle to ensure ideal wetting between the sticky surface of the strip sample and the substrate surface (one example is a 2.2 kg roller with a speed of 10 mm / s and two revolutions in each direction). After the assembly is prepared, it should be allowed to rest for a specified period before starting the peel test.

[0050] When the peel test is ready to be performed, the peel assembly is attached to the tensile tester. The free end of the strip specimen is secured in one of the tester's grips, and the steel substrate is secured in the other grip. The tester peels the strip specimen from the steel substrate at a specified speed at an angle of 180 degrees. An example peel speed is 100 mm / min.

[0051] Overall, the adhesion of a strip sample on an oily substrate can be characterized by two aspects of the results from such a peel test. One is the average peel force in Newtons over a peel length of at least 100 mm, but not including the first 25 mm. The other is the separation pattern between the strip sample and the oily substrate as a result of the peel. The pattern can be adhesive (i.e., the strip sample itself separates so that at least a portion of one surface of the strip remains adhered to the substrate) or adhesive (i.e., there is separation at the interface between the strip sample and the substrate). If the separation pattern is a mixture of adhesive and sticky, the percentage of the area with sticky or sticky separation should be estimated.

[0052] The adhesion of the strip sample can be judged from the above two aspects of the results. Usually, it is desirable to have either a higher peel force or a more adhesive separation mode, or both. Adhesive separation is preferred because it indicates that the bonding force between the strip sample and the substrate exceeds the inherent strength of the sample itself, and therefore the sample is less likely to delaminate or separate from the substrate. 100% adhesive separation achieved with a high peel force is most preferred.

[0053] Some exemplary results are shown in Table 7 below. Table 7 [Table 7]

Claims

1. 1. An improved constrained layer vibration damping patch comprising: Constraint layer, and a damping layer, the damping layer being composed of a butyl rubber composite, a tackifier, a plasticizer, and a filler composite; the butyl rubber composite is composed of a partially crosslinked butyl rubber and an isobutylene-isoprene butyl rubber composite; The isobutylene-isoprene butyl rubber composite is composed of isobutylene-isoprene butyl rubber and recycled isobutylene-isoprene butyl rubber. Improved constrained layer vibration damping patch.

2. 10. The improved constraining layer vibration damping patch of claim 1 further comprising a release liner.

3. 10. The improved constraining layer vibration-damping patch of claim 1 further comprising a colorant.

4. 4. The improved constraining layer vibration damping patch of claim 1, 2, or 3, wherein the tackifier is selected from a rosin ester resin or an aliphatic hydrocarbon resin.

5. 5. The improved constraining layer vibration damping patch of claims 1, 2, 3, or 4, wherein the plasticizer comprises at least one isobutylene-butene copolymer, pure isobutene homopolymer, or a mixture thereof.

6. 6. The improved constrained layer vibration damping patch of claim 1, 2, 3, 4, or 5, wherein said filler composite is comprised of at least one functional filler and a general filler.

7. 7. The improved constraining layer vibration damping patch of claim 6, wherein said at least one functional filler comprises calcium oxide (CaO), talc, kaolin clay, or mixtures thereof.

8. The common filler is calcium carbonate (CaCO ３ 7. The improved constrained layer vibration damping patch of claim 6, comprising:

9. 9. The improved constrained layer vibration-damping patch of claim 1, 2, 3, 4, 5, 6, 7, or 8, wherein the damping layer is substantially free of enhancers.

10. 10. The improved constrained layer vibration-damping patch of claim 1, 2, 3, 4, 5, 6, 7, 8, or 9, wherein the damping layer does not comprise an ethylene copolymer.

11. 1. A vibration damping layer composition comprising: about 10 to about 15 weight percent of a butyl rubber composition; about 1 to about 5 weight percent of a tackifier; about 20 to about 25 weight percent plasticizer; about 60 to about 65 weight percent filler, and about 0.01 to 1 weight percent colorant; Substantially free of curatives and free of ethylene copolymers; Vibration damping layer composition.

12. 1. An improved constrained layer vibration damping system comprising:

1. An improved constrained layer vibration damping patch comprising: release liner, Constraint layer, and a damping layer including a first surface and a second surface; a constrained layer vibration damping patch, a metal substrate to which said improved constrained layer vibration damping patch is adhered; Including, the damping layer includes a first surface and a second surface; the constraining layer is in physical communication with the first surface of the damping layer; the release liner is in physical communication with the second surface of the damping layer; the damping layer is adhered to the metal substrate such that when the release liner is removed from the second surface of the damping layer to expose the second surface of the damping layer, the second surface of the damping layer is in physical communication with the metal substrate and the damping layer is intermediate the constraining layer and the metal substrate; the damping layer comprises about 10 to about 15 wt % of a butyl rubber composite; The butyl rubber composite comprises polyisobutylene butyl rubber and an isobutylene-isoprene butyl rubber composite. Improved constrained layer vibration damping system.

13. 13. The improved constrained layer vibration damping system of claim 12, wherein said metal substrate comprises steel having a protective coating to inhibit rust.

14. 14. The improved constrained layer vibration damping system of claim 13, wherein the protective coating is comprised of between about 60 weight percent and about 70 weight percent mineral oil.

15. 15. The improved constrained layer vibration damping system of claim 12, 13, or 14, wherein the constrained layer vibration damping system exhibits a peel adhesion strength of between 9 N / cm and 13 N / cm when measured in accordance with ISO 8510.

Images