Two component (epoxy/amine) structural foam-in-place material
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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.
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Citations
39 Claims
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1-19. -19. (canceled)
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20. A method for producing a foamed article, comprising the steps of:
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providing an epoxy component that includes;
i) an epoxy resin;
ii) a thixotropic additive;
iii) a reactive diluent;
iv) hollow glass microspheres; and
v) a blowing agent, the blowing agent being expandable microspheres;
providing a substantially liquid amine component that includes;
i) an aliphatic amine curing agent; and
ii) thixotropic additive;
combining and dispensing said epoxy component and said amine component to form a reactive mixture wherein;
i) the epoxy component and the amine component are formed as prior to forming the reactive mixture;
ii) the epoxy component and the amine component react together exothermically to produce heat;
iii) the admixture exhibits higher viscosity a zero shear rate and decreased viscosity at higher shear rate; and
iv) the heat causes the expandable microspheres to soften and expand;
providing the reactive mixture within an automotive body cavity contemporaneously with the formation of the mixture or shortly thereafter. - View Dependent Claims (21, 22, 23, 24, 25, 26, 27, 28)
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29. A method for producing a foamed article, comprising the steps of:
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providing an epoxy component that includes;
i) a bisphenol epoxy resin, the epoxy resin being from 35% to 99% by weight of the epoxy component;
ii) a thixotropic additive, the thixotropic additive being a fumed silica;
iii) an oxide;
iv) a reactive diluent;
v) liquid nitrile rubber;
vi) hollow glass microspheres;
vii) clay;
viii) a pigment; and
ix) a blowing agent, the blowing agent being expandable microspheres;
providing a substantially liquid amine component that includes;
i) an aliphatic amine curing agent;
ii) thixotropic additive including fumed silica or wollastonite; and
iii) rubber, the rubber being a liquid nitrile rubber;
combining and dispensing said epoxy component and said amine component at around room temperature to form a reactive mixture wherein;
i) the epoxy component and the amine component are formed prior to forming the reactive mixture;
ii) the epoxy component and the amine component react together exothermically to produce heat;
iii) the admixture exhibits higher viscosity a zero shear rate and decrease viscosity at higher shear rate; and
iv) the heat causes the expandable microspheres to soften and expand without addition of external heat;
providing the reactive mixture within an automotive body cavity contemporaneously with the formation of the mixture or shortly thereafter; and
allowing the reactive mixture to cure to form said foamed article. - View Dependent Claims (30, 31, 32, 33, 34, 35)
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36. A method for producing a foamed article, comprising the steps of:
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providing a substantially liquid epoxy component that includes;
i) an epoxy resin, the epoxy resin being a glycidyl ether of bisphenol A, the epoxy resin being from 65% to 98% by weight of the epoxy component;
ii) a thixotropic additive, the thixotropic additive being a fumed silica;
iii) calcium oxide;
iv) a reactive diluent, the diluent being a glycidyl ether;
v) liquid nitrile rubber;
vi) hollow glass microspheres;
vii) clay;
viii) a pigment; and
ix) a blowing agent, the blowing agent being expandable microspheres formed of thermoplastic shells filled with a solvent core;
providing a substantially liquid amine component that includes;
i) an aliphatic amine curing agent;
ii) thixotropic additive including fumed silica and wollastonite;
iii) hollow glass microspheres; and
iv) rubber, the rubber being a liquid nitrile rubber;
combining and dispensing said epoxy component and said amine component at around room temperature to form a reactive mixture wherein;
i) the epoxy component and the amine component are formed as separate liquids prior to forming the reactive mixture;
ii) the epoxy component and the amine component react together exothermically to produce heat;
iii) the admixture exhibits higher viscosity a zero shear rate and decrease viscosity at higher shear rate; and
iv) the heat causes the thermoplastic shell filled with a solvent core to soften and expand due to gas pressure from said solvent core without addition of external heat;
providing the reactive mixture within an automotive body cavity contemporaneously with the formation of the mixture or shortly thereafter; and
allowing the reactive mixture to cure to form said foamed article wherein said foamed article is capable of substantial plastic deformation after curing without substantial loss of strength modulus and wherein said foamed article has a glass transition temperature greater than 200°
F. after such plastic deformation. - View Dependent Claims (37, 38, 39)
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Specification