EPOXY/ELASTOMER ADDUCT, METHOD OF FORMING SAME AND MATERIALS AND ARTICLES FORMED THEREWITH

• US 20070088138A1
• Filed: 11/16/2006
• Published: 04/19/2007
• Est. Priority Date: 03/04/2003
• Status: Abandoned Application

• Current Assignee: L&L Products Inc.
• Original Assignee: L&L Products Inc.
• Inventors: Chmielewski, Craig, Czaplicki, Michael, Carlson, David, Hable, Christopher
• Application Number:
  US11/560,486
• Publication Number:
  US 20070088138A1
• Time in Patent Office: Days
• US Class Current: 525/524
• CPC Class Codes: C08G 59/18 Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
• CPC Class Codes: C08G 59/186 with acids
• CPC Class Codes: C08G 59/4253 Rubbers
• CPC Class Codes: C08J 2363/00 Characterised by the use of epoxy resins; Derivatives of epoxy resins
• CPC Class Codes: C08J 2409/02 Copolymers with acrylonitrile
• CPC Class Codes: C08J 2463/00 Characterised by the use of epoxy resins; Derivatives of epoxy resins
• CPC Class Codes: C08J 9/0061 characterized by the use of several polymeric components
• CPC Class Codes: C08J 9/103 Azodicarbonamide

Abstract

An epoxy/elastomer adduct, a method of forming the adduct and materials and articles incorporating the adduct are disclosed. The adduct preferably includes up to about 60% by weight of an elastomeric component, up to about 90% by weight of an epoxy component and optionally one or more additives.

Claims

1-23. -23. (canceled)

24. :

A method of forming an epoxy/elastomer adduct, the method comprising;

providing an epoxy component;

providing an elastomer, the elastomer being a nitrile rubber, wherein at least one of the epoxy component and the elastomer is a solid;

melt mixing the epoxy component with the elastomer such that the epoxy component reacts with the elastomer to form the adduct, the elastomer being at least 15% by weight of the adduct.

25. :

A method as in claim 24 wherein the melt mixing is accomplished substantially without solvent.

26. :

A method as in claim 24 melt mixing in the presence of a catalyst the catalyst being selected from a phosphine and an iodide.

27. :

A method as in claim 24 wherein the epoxy component is between about 70% and about 85% by weight of the adduct and the elastomer is at least about 20% by weight of the adduct.

28. :

A method as in claim 24 wherein the epoxy component is provided as a phenolic resin and wherein the adduct exhibits a viscosity of at least about 500 Pa-s at a temperature of about 100°

C. and a shear rate of 400 s<sup>−

1</sup>.

29. :

A method as in claim 24 wherein the epoxy component has a molecular weight between about 900 amu and about 1300 amu, an epoxy equivalent weight between about 100 EEW g/mol and about 1000 EEW and a softening point between about 65°

C. and about 75°

C.

30. :

A method as in claim 24 wherein the elastomer is between about 15% and about 35% by weight of the adduct and the elastomer has a carboxyl content of between about 0.05 and about 0.1 equivalents per hundred rubber.

31. :

A method as in claim 24 further comprising a reactive diluent wherein the adduct exhibits a viscosity of at least about 600 Pa-s at a temperature of about 100°

C. and a shear rate of 400 s<sup>−

1</sup>.

32. :

A method as in claim 24 wherein the step of mixing includes introducing the epoxy component, in a solid state, and the elastomer, in a solid state, to an extruder, which melts and mixes the epoxy component with the elastomer.

33. :

A method of forming an epoxy/elastomer adduct, the method comprising;

providing a solid epoxy component, wherein the epoxy component is provided as a phenolic resin including at least one of a solid bisphenol-A epichlorohydrin ether polymer or a solid bishpenol-A epoxy resin;

providing a solid elastomer, the elastomer being a carboxylated butadiene nitrile rubber;

melt mixing, substantially without solvent, the epoxy component with the elastomer in the presence of a catalyst such that the epoxy component reacts with the elastomer to form the adduct with the elastomer being at least 15% by weight of the adduct and the epoxy component being between about 50% and about 90% by weight of the adduct, the catalyst being selected from a phosphine and an iodide; and

solidifying the adduct.

34. :

A method as in claim 33 wherein the elastomer is at least 20% by weight of the adduct.

35. :

A method as in claim 33 Wherein the elastomer is between about 30% and about 40% by weight of the adduct.

36. :

A method as in claim 33 wherein the epoxy component has a molecular weight between about 900 amu and about 1300 amu, an epoxy equivalent weight between about 100 EEW g/mol and about 1000 EEW and a softening point between about 65°

C. and about 75°

C.

37. :

A method as in claim 33 wherein the elastomer is between about 15% and about 35% by weight of the adduct and the elastomer has a carboxyl content of between about 0.05 and about 0.1 equivalents per hundred rubber.

38. :

A method as in claim 33 further comprising a reactive diluent wherein the adduct exhibits a viscosity of at least about 600 Pa-s at a temperature of about 100°

C. and a shear rate of 400 s<sup>−

1</sup>.

39. :

A method as in claim 33 wherein the step of mixing includes introducing the epoxy component, in a solid state, and the elastomer, in a solid state, to an extruder, which melts and mixes the epoxy component with the elastomer.

40. :

A method as in claim 33 further comprising mixing the adduct with a filler, a curing agent and a blowing agent.

41. :

A method of forming an epoxy/elastomer adduct, the method comprising;

providing a solid epoxy component composed substantially entirely of a solid bisphenol-A epoxy resin, the epoxy resin having a molecular weight of between about 400 amu and about 1500 amu, the epoxy resin having between about 200 EEW and about 750 EEW, the epoxy resin having a softening point between about 45°

C. and about 85°

C.;

providing a solid elastomer, the elastomer being a carboxylated butadiene nitrile rubber, the elastomeric component having a mooney viscosity of between about 15 and about 40 at a temperature of 100°

C. and having a carboxyl content of between about 0.01 EPHR and about 0.1 EPHR and being between about 20% and about 40% by weight nitrile, wherein;

melt mixing, substantially without solvent, the epoxy component with the elastomer in the presence of a catalyst such that the epoxy component reacts with the elastomer to form the adduct with the elastomer being at least 20% by weight of the adduct and the epoxy component being is between about 70% and about 85% by weight of the adduct, the catalyst being selected from triphenyl phosphine or ethyl triphenyl phosphonium idodide; and

solidifying the adduct substantially by itself.

42. :

A method as in claim 41 wherein the mixing step produces an adduct that exhibits a viscosity of at least about 600 Pa-s at a temperature of about 100°

C. and a shear rate of 400 s<sup>−

1</sup>.

43. :

A method as in claim 42 wherein the step of mixing includes introducing the epoxy component, in a solid state, and the elastomer, in a solid state, to an extruder, which melts and mixes the epoxy component with the elastomer.