Creation of epoxy-based foam-in-place material using encapsulated metal carbonate
First Claim
1. A method for producing a foamed article, comprising the steps of:
- providing an epoxy resin formulation, said formulation comprising a pre-mixed epoxy resin and an encapsulated metal salt core;
providing an acid; and
combining said resin formulation and said acid to form a reactive mixture and allowing said acid to catalyze polymerization of said resin formulation and react with said coated particulate to generate a blowing gas to form voids in said polymerized epoxy resin.
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Accused Products
Abstract
The invention and formulation relates to methods, materials, and products for foam-in-place materials comprising a two-component foam-in-place structural material for producing a foamed product. A first component of the system includes an epoxy-based resin preferably formulated with a coated particles, such as a metal salt, a metal carbonate encapsulated within a wax, or a polymer, (e.g., Thermoset, thermoplastic, or mixture). The metal carbonate particle may be encapsulated within a wax, shell or skin that will change state to expose the core to chemically react for initiating the production of gas for blowing. 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 acid with the epoxy component causes the thermoplastic shell, skin, or wax encapsulating a metal carbonate core to soften or melt thereby exposing the metal carbonate to the reactive mixture.
67 Citations
17 Claims
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1. A method for producing a foamed article, comprising the steps of:
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providing an epoxy resin formulation, said formulation comprising a pre-mixed epoxy resin and an encapsulated metal salt core;
providing an acid; and
combining said resin formulation and said acid to form a reactive mixture and allowing said acid to catalyze polymerization of said resin formulation and react with said coated particulate to generate a blowing gas to form voids in said polymerized epoxy resin. - View Dependent Claims (2, 3, 15)
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4. A method for producing a foamed article, comprising the steps of:
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providing an epoxy resin formulation, said formulation having an epoxy resin and an encapsulated metal carbonate core;
providing phosphoric acid; and
combining said resin formulation and said phosphoric acid to form a reactive mixture and allowing said phosphoric acid to catalyze polymerization of said resin formulation and react with said metal carbonate core to generate a blowing gas to form voids in said polymerized epoxy resin. - View Dependent Claims (5, 6, 7, 8, 9, 10, 11, 12, 16)
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13. A method for producing a foamed article, comprising the steps of:
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providing an epoxy resin;
providing a metal carbonate core encapsulated by a meltable solid;
combining said epoxy resin and said metal carbonate core encapsulated by a polymer to form an epoxy-based formulation;
providing phosphoric acid;
combining said epoxy-based formulation and said phosphoric acid to form a reactive mixture and allowing said phosphoric acid to catalyze polymerization of said epoxy-based formulation and react with said metal carbonate core to generate a blowing gas to form voids in said polymerized epoxy resin. - View Dependent Claims (14, 17)
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Specification