Wax-modified thermosettable compositions

• US 6,403,222 B1
• Filed: 09/22/2000
• Issued: 06/11/2002
• Est. Priority Date: 09/22/2000
• Status: Expired due to Fees

• Current Assignee: Henkel Corporation (Henkel AG & Co KGaA)
• Original Assignee: Henkel Corporation (Henkel AG & Co KGaA)
• Inventors: Harrison, Bruce L.
• Primary Examiner(s): Dawson, Robert
• Assistant Examiner(s): Feely, Michael J
• Application Number:
  US09/668,671
• Time in Patent Office: 627 Days
• Field of Search: 428/413, 428/414, 428/416, 428/418, 428/304.4, 428/313.3, 521/76, 521/82, 521/98, 521/99, 521/128, 523/400, 523/427, 523/428, 523/465
• US Class Current: 428/418
• CPC Class Codes: B32B 15/08 of synthetic resin
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: C08J 2363/00 Characterised by the use of epoxy resins; Derivatives of epoxy resins
• CPC Class Codes: C08J 2491/00 Characterised by the use of oils, fats or waxes; Derivatives thereof
• CPC Class Codes: C08J 9/0061 characterized by the use of several polymeric components
• CPC Class Codes: C08K 5/0091 Complexes with metal-heteroatom-bonds
• CPC Class Codes: C08L 63/00 Compositions of epoxy resins; Compositions of derivatives of epoxy resins
• CPC Class Codes: C08L 91/06 Waxes
• CPC Class Codes: C08L 91/08 Mineral waxes
• CPC Class Codes: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/249971 Preformed hollow element-containing
• CPC Class Codes: Y10T 428/31511 Of epoxy ether
• CPC Class Codes: Y10T 428/31529 Next to metal

Abstract

Waxes, particularly paraffin and microcrystalline waxes, can act as corrosion inhibitors when added at low levels to compositions based on thermosettable resins such as epoxy resins. When such wax-modified thermosettable compositions are used to coat a metallic surface, enhanced protection of the metallic surface against corrosion due to environmental exposure such as salt spray is obtained. The thermosettable compositions are particularly useful in expandable or foamable form for imparting structural reinforcement to hollow metal parts such as automotive components.

Claims

1. A thermosettable composition comprising:

(a) one or more thermosettable resins;

(b) one or more curatives;

(c) one or more waxes; and

(d) at least one member selected from the group consisting of hollow glass microspheres and alkaline earth metal-modified silicates.

2. The thermosettable composition of claim 1 wherein at least one of the waxes is selected from the group consisting of paraffin waxes and microcrystalline waxes.

3. The thermosettable composition of claim 1 wherein said waxes comprise from about 0.1 to about 1% by weight of the thermosettable composition.

4. The thermosettable composition of claim 1 additionally comprising one or more coupling agents.

5. The thermosettable composition of claim 4 wherein at least one of the coupling agents is selected from the group consisting of organic titanates and organic zirconates.

6. The thermosettable composition of claim 1 wherein at least one of the thermosettable resins is an epoxy resin.

7. The thermosettable composition of claim 1 wherein at least one of the thermosettable resins is a glycidyl ether of a polyhydric phenol.

8. The thermosettable composition of claim 1 additionally comprising one or more blowing agents.

9. The thermosettable composition of claim 8 wherein at least one of the blowing agents is selected from the group consisting of expandable microspheres, azo compounds and sulfonyl hydrazides.

10. The thermosettable composition of claim 1 wherein at least one of the curatives is selected from the group consisting of guanidines, amine-epoxy adducts, and boron trichloride amine adducts.

11. The thermosettable composition of claim 1 comprising from about 10 to about 30 weight percent hollow glass microspheres.

12. The thermosettable composition of claim 1 additionally comprising one or more fillers.

13. The thermosettable composition of claim 12 wherein at least one of the fillers is selected from the group consisting of glass fibers, polymeric fibers, mica, wollastonite, and calcium carbonate.

14. The thermosettable composition of claim 1 additionally comprising one or more thixotropic agents.

15. The thermosettable composition of claim 14 wherein at least one of the thixotropic agents is fumed silica.

16. The thermosettable composition claim 1 comprising one or more alkaline earth metal-modified silicates selected from calcium ion exchanged amorphous silica gels.

17. A thermoset obtained by curing the thermosettable composition of claim 1.

18. A composite comprised of a solid article having a metal surface and the thermoset of claim 17, said thermoset being adhered to at least a portion of said metal surface.

19. A composite comprised of a solid article having a metal surface and the thermosettable composition of claim 1, said thermosettable composition being adhered to at least a portion of said metal surface.

20. A foamable thermosettable composition comprising:

21. A foam obtained by heating and curing the foamable thermosettable composition of claim 20.

22. A composite comprised of a solid article having a metal surface and the foam of claim 21, said foam being adhered to at least a portion of said metal surface.

23. A composite comprised of a solid article having a metal surface and the foamable thermosettable composition of claim 20, said foamable thermosettable composition being adhered to at least a portion of said metal surface.

24. A composite comprised of a solid article having a metal surface and a foam obtained by heating and curing a foamable thermosettable composition comprising:

(a) from about 30 to about 70% by weight of one or more epoxy resins, at least one of said epoxy resins being a glycidyl ether of a polyhydric phenol;

(b) from about 0.05 to about 10% by weight of one or more curatives, at least one of said curatives being selected from the group consisting of guanidines, amine-epoxy adducts, and boron trichloride amine adducts;

(c) from about 0.1 to about 5% by weight of one or more blowing agents, at least one of said blowing agents being selected from the group consisting of expandable microspheres, azo compounds, and sulfonyl hydrazides; and

(d) from about 0.1 to about 1% by weight of one or more waxes, at least one of said waxes being selected from the group consisting of paraffin waxes and microcrystalline waxes.

25. A composite comprised of a solid article having a metal surface and a foamable thermosettable composition comprised of:

(a) from about 30 to about 70% by weight of one or more epoxy resins, at least one of said epoxy resins being a glycidyl ether of a polyhydric phenol;

(b) from about 0.05 to about 10% by weight of one or more curatives, at least one of said curatives being selected from the group consisting of guanidines, amine epoxy adducts, and boron trichloride amine adducts;

(c) from about 0 1 to about 5% by weight of one or more blowing agents, at least one of said blowing agents being selected from the group consisting of expandable microspheres, azo compounds, and sulfonyl hydrazides, and

(d) from about 0.1 to about 1% by weight of one or more waxes, at least one of said waxes being selected from the group consisting of paraffin waxes and microcrystalline waxes;

said foamable thermosettable composition being adhered to at least a portion of said metal surface.

26. A method of inhibiting corrosion of a metal surface in a conposite in contact with a foam obtained by heating and curing a foamable thermosettable composition comprising one or more epoxy resins, one or more curatives and one or more blowing agents, said method comprising incorporating into the foamable thermosettable composition an amount of one or more waxes effective to reduce corrosion of said metal surface upon exposure of the composite to moisture.