David Joseph Kosal

US Patent:

6787579, Sep 7, 2004

Filed:

May 2, 2001

Appl. No.:

09/847252

Inventors:

Michael J. Czaplicki - Rochester MI
David J. Kosal - Richmond MI
Keith Madaus - Goodwells MI

Assignee:

LL Products, Inc. - Romeo MI

International Classification:

C08J 932

US Classification:

521 54, 521178, 521135

Abstract:

The present invention relates to methods, materials, and products for forming a foamed product, comprising the steps of combining an epoxy-based component with an amine-based component. The epoxy component is cross-linked through a polymerization reaction catalyzed by the amine formulation. In this regard, a reactive mixture or exothermic reaction is created between the epoxy component and the amine component when combined. The heat generated by the exothermic reaction softens a thermoplastic shell of a blowing agent formulated within the epoxy component thereby enabling a solvent core within the thermoplastic shell of the blowing agent to expand from the heat generated by the exothermic reaction.

US Patent:

6846559, Jan 25, 2005

Filed:

Mar 11, 2003

Appl. No.:

10/386287

Inventors:

Michael J. Czaplicki - Rochester MI, US
David Kosal - Richmond MI, US

Assignee:

L&L Products, Inc. - Romeo MI

International Classification:

B32B 2738

US Classification:

428355EP, 428336, 4283014, 521135, 523443, 525119, 525122, 525530, 525531

Abstract:

An activatable (e. g. , heat expandable) material and articles incorporating the same is disclosed. The material includes an epoxy resin; an epoxy/elastomer hybrid or reaction product; a blowing agent; a curing agent; and optionally, a filler. In preferred embodiments, the material includes aramid fiber, nanoclay or both.

US Patent:

6887914, May 3, 2005

Filed:

Sep 4, 2002

Appl. No.:

10/234902

Inventors:

Michael J. Czaplicki - Rochester MI, US
David J. Kosal - Richmond MI, US
Jeanne Antrim - Lake Orion MI, US

Assignee:

L&L Products, Inc. - Romeo MI

International Classification:

C08J009/10

US Classification:

521178, 156330, 156547, 156548, 428196, 4283044, 4283055, 4283084, 4283227

Abstract:

The present invention relates to a material, method, and application for reinforcement of structural members, especially joints such as a hem flange joint of an automobile. The method and material of the present invention comprises of combining, in parts by weight: less than about twenty percent (

US Patent:

6890964, May 10, 2005

Filed:

Apr 10, 2002

Appl. No.:

10/119446

Inventors:

Michael J. Czaplicki - Rochester MI, US
David J. Kosal - Richmond MI, US
Keith Madaus - Goodwells MI, US

Assignee:

L&L Products, Inc. - Romeo MI

International Classification:

C08J009/00
C08J009/02

US Classification:

521 54, 521 97, 521135, 521178

Abstract:

A two-component foam-in-place structural material for producing a foamed product. The first component of the system includes an epoxy-based resin preferably formulated with a physical blowing agent particulate material. The physical blowing agent core is encapsulated within a shell or skin that will change state. The second component is an acid that is capable of initiating polymerization of the resin. A reactive mixture is achieved through the combination of the first and second components wherein heat from the exothermic reaction of the epoxy component caused by the acid in turn causes the thermoplastic shell having a solvent core to soften and increase in size due to gas pressure and change in state of the shell thereby foaming the reactive mixture.

US Patent:

7290828, Nov 6, 2007

Filed:

Jun 2, 2005

Appl. No.:

11/143068

Inventors:

David J. Kosal - Richmond MI, US
Kevin Hicks - Harrison Township MI, US
David Carlson - Rochester Hills MI, US
Michael J. Czaplicki - Rochester MI, US
Serge Bieber - Haegen, FR
Dominique Busseuil - Lux, FR

Assignee:

Zephyros, Inc. - Romeo MI

International Classification:

B29C 44/06
B60R 27/00

US Classification:

29618702, 264 465, 264 466, 264273, 428 71

Abstract:

There is disclosed a system and method of employing a porous container for sealing, baffling, reinforcing or a combination thereof. According to the method, a porous container having one or more openings is provided. An expandable material is associated with the container and is preferably placed within the container. Thereafter, the expandable material is expanded to contact and adhere to a structure of an article of manufacture (e. g. , an automotive vehicle).

US Patent:

7438782, Oct 21, 2008

Filed:

Jun 7, 2006

Appl. No.:

11/422705

Inventors:

David Sheasley - Rochester MI, US
David Kosal - Richmond MI, US
Jeanne Antrim - Lake Orion MI, US

Assignee:

Zephyros, Inc. - Romeo MI

International Classification:

B29C 65/00
B32B 37/00
C08F 283/00
C08G 59/14
C08L 63/00

US Classification:

156293, 525524

Abstract:

An activatable material and articles incorporating the same is disclosed. The activatable material includes at least two of epoxy resin; impact modifier; blowing agent; curing agent; and filler. The activatable material is preferably used for sealing, baffling, adhering or reinforcing an article of manufacture such as an automotive vehicle.

US Patent:

7469459, Dec 30, 2008

Filed:

Sep 15, 2004

Appl. No.:

10/941553

Inventors:

David J. Kosal - Richmond MI, US
Kevin Hicks - Harrison Township MI, US
David Carlson - Rochester Hills MI, US
Michael J. Czaplicki - Rochester MI, US
Serge Bieber - Haegen, FR
Dominique Busseuil - Lux, FR

Assignee:

Zephyros, Inc. - Romeo MI

International Classification:

B21D 39/00
B23P 19/04

US Classification:

294551, 298972

Abstract:

There is disclosed a system and method of employing a porous container for sealing, baffling, reinforcing or a combination thereof. According to the method, a porous container having one or more openings is provided. An expandable material is associated with the container and is preferably placed within the container. Thereafter, the expandable material is expanded to contact and adhere to a structure of an article of manufacture (e. g. , an automotive vehicle).

US Patent:

7473715, Jan 6, 2009

Filed:

Nov 10, 2004

Appl. No.:

10/985197

Inventors:

Michael J. Czaplicki - Rochester MI, US
David J. Kosal - Richmond MI, US
Kevin Hicks - Harrison Township MI, US

Assignee:

Zephyros, Inc. - Romeo MI

International Classification:

C08J 9/08
C08J 9/32
B01J 13/02

US Classification:

521 54, 521 76, 521 83, 521100, 521135, 521178

Abstract:

The present invention relates to methods, materials, and products for forming a foamed product, comprising the steps of combining an epoxy-based component with an amine-based component. The epoxy component is cross-linked through a polymerization reaction catalyzed by the amine formulation. In this regard, an reactive mixture or exothermic reaction is created between the epoxy component and the amine component when combined. The heat generated by the exothermic reaction softens a thermoplastic shell of a blowing agent formulated within the epoxy component thereby enabling a solvent core within the thermoplastic shell of the blowing agent to expand from the heat generated by the exothermic or reactive mixture.