Patent ID: 8702889

Claim:
A method of forming and applying an adhesive material comprising the steps of: forming a mixture including: i) locating in a container an epoxy resin in an amount of from about 15% to about 40% by weight of the mixture, at least 50% of which is provided as a liquid epoxy, the liquid epoxy having a viscosity of at least 8000 cps at 23° C.; ii) locating into the container a plurality of pellets of an impact modifier comprising a methacrylate-butadiene-styrene core/shell polymer in an amount of less than about 30% by weight of the mixture; iii) locating into the container an epoxidized polysulfide flexibilizer in an amount of at least 5% to about 45% by weight for maintaining impact strength at low temperatures while minimizing the reduction of glass transition temperature; and iv) locating into the container a curing agent; v) locating into the container a clay filler, wherein, in the step of forming the mixture, the core/shell polymer and at least a portion of the epoxy resin are mixed in solid form prior to the introduction of any liquid components; locating the adhesive material upon a first surface; and activating the adhesive material to bond the adhesive material to a second surface; forming a discrete secondary phase within the adhesive material upon activation, whereby a portion of the adhesive material including the core/shell polymer separates itself from the rest of the adhesive material.