Two component (epoxy/amine) structural foam-in-place material

• US 20050119372A1
• Filed: 11/10/2004
• Published: 06/02/2005
• Est. Priority Date: 05/02/2001
• Status: Active Grant

• Current Assignee: Zephyros, Inc.
• Original Assignee: L&L Products Inc.
• Inventors: Hicks, Kevin, Kosal, David J., Czaplicki, Michael J.
• Granted Patent: US 7,473,715 B2
• Time in Patent Office: Days
• US Class Current: 523/400
• CPC Class Codes: C08J 2203/22 Expandable microspheres, e.g. Expancel®
• CPC Class Codes: C08J 2363/00 Characterised by the use of epoxy resins; Derivatives of epoxy resins
• CPC Class Codes: C08J 9/32 from compositions containing microballoons, e.g. syntactic foams

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.

Claims

1. A method for producing a foamed article, comprising the steps of:

providing an epoxy component, said epoxy component including an epoxy resin, a blowing agent having a thermoplastic shell filled with a solvent core;

providing an amine component, said amine formulation including at least one amine;

combining said epoxy component and said amine component to form a reactive mixture and allowing said thermoplastic shell filled with a solvent core to soften from amine-epoxy exotherm and then expand due to gas pressure from said solvent core;

wherein one or both of the epoxy component and the amine component include an ammonium clay.

2. A method as in claim 1, wherein the epoxy resin comprises from about 35% to about 95% of the epoxy component.

3. A method as in claim 1, wherein the epoxy resin and the ammonium clay are combined prior to adding the blowing agent when forming the epoxy component.

4. A method as in claim 1, wherein the ammonium clay includes at least one of smectite, sepiolite or a chloride.

5. A method as in claim 1, wherein the reactive admixture expands greater than 50% of its original unexpanded state to form the foamed article and the foamed article has a compressive modulus greater than about 700 MPa.

6. A method as in claim 1, wherein the reactive mixture includes a aliphatic acrylic ester.

7. A method as in claim 1, wherein the reactive mixture includes a butyl acrylatel methyl methacrylate.

8. A method as in claim 1, wherein the reactive mixture includes an additive selected from glass microspheres or ceramic microspheres.

9. A method for producing a foamed article, comprising the steps of:

providing an epoxy component, said epoxy component including;

i) an epoxy resin that includes at least one of a bisphenol A epoxy resin, an isopropyl epoxy resin and a polyglycol diglycidyl ether;

ii) a blowing agent having a thermoplastic shell filled with a solvent core;

iii) a butyl acrylate/methyl methacrylate modifier;

iv) an acrylic ester; and

v) an ammonium clay

providing an amine component, said amine formulation including;

i) at least one amine selected from a piperazine amine and an amidoamine; and

ii) an ammonium clay;

combining said epoxy component and said amine component to form a reactive mixture and allowing said thermoplastic shell filled with a solvent core to soften from amine-epoxy exotherm and then expand due to gas pressure from said solvent core.

10. A method as in claim 9, wherein the epoxy resin comprises from about 35% to about 95% of the epoxy component.

11. A method as in claim 9, wherein the epoxy resin and the ammonium clay are combined prior to adding the blowing agent when forming the epoxy component.

12. A method as in claim 9, wherein the ammonium clay includes at least one of smectite, sepiolite or a chloride.

13. A method as in claim 9, wherein the foamed article exhibt the reactive admixture expands greater than 50% of its original unexpanded state to form the foamed article and the foamed article has a compressive modulus greater than about 700 MPa.

14. A method as in claim 9, wherein the reactive mixture includes an additive selected from glass microspheres or ceramic microspheres.

15. A method for producing a foamed article, comprising the steps of:

providing an epoxy component, said epoxy component including;

i) an epoxy resin that includes a combination of a bisphenol A epoxy resin, an isopropyl epoxy resin and a polyglycol diglycidyl ether;

ii) a blowing agent having a thermoplastic shell filled with a solvent core;

iii) a butyl acrylate/methyl methacrylate modifier;

iv) a acrylic ester; and

v) an alkyl quaternary ammonium clay that includes smectite, sepiolite and an ammonium chloride;

providing an amine component, said amine formulation including;

i) at least one amine selected from a piperazine amine and an amidoamine; and

ii) an alkyl quaternary ammonium clay that includes smectite, sepiolite and an ammonium chloride;

combining said epoxy component and said amine component to form a reactive mixture and allowing said thermoplastic shell filled with a solvent core to soften from amine-epoxy exotherm and then expand due to gas pressure from said solvent core.

16. A method as in claim 15, wherein the epoxy resin comprises from about 35% to about 95% of the epoxy component.

17. A method as in claim 15, wherein the epoxy resin and the ammonium clay are combined prior to adding the blowing agent when forming the epoxy component.

18. A method as in claim 15, wherein the reactive admixture expands greater than 50% of its original unexpanded state to form the foamed article and the foamed article has a compressive modulus greater than about 700 MPa.

19. A method as in claim 15, wherein the reactive mixture includes an additive selected from glass microspheres or ceramic microspheres.