Activatable material

• US 6,846,559 B2
• Filed: 03/11/2003
• Issued: 01/25/2005
• Est. Priority Date: 04/01/2002
• Status: Expired due to Term

• Current Assignee: Zephyros, Inc.
• Original Assignee: L&L Products Inc.
• Inventors: Kosal, David, Czaplicki, Michael J.
• Primary Examiner(s): Buttner, David J.
• Assistant Examiner(s): KEEHAN, CHRISTOPHER M
• Application Number:
  US10/386,287
• Publication Number:
  US 20030186049A1
• Time in Patent Office: 686 Days
• Field of Search: 428/355.EP, 428/355.CN, 428/301.4, 428/336, 428/355.BL, 521/135, 523/443, 525/119, 525/122, 525/530, 525/531, 525/526
• US Class Current: 428/355.0EP
• CPC Class Codes: C08F 283/10 on to polymers containing more than one epoxy radical per molecule C08F283/004 takes precedence
• CPC Class Codes: C08G 59/4021 Ureas; Thioureas; Guanidines; Dicyandiamides
• CPC Class Codes: C08G 59/4261 Macromolecular compounds obtained by reactions involving only unsaturated carbon-to-carbon bindings C08G59/4253 takes precedence
• CPC Class Codes: C08L 2666/02 Organic macromolecular compounds, natural resins, waxes or and bituminous materials
• CPC Class Codes: C08L 2666/14 Macromolecular compounds according to C08L59/00 - C08L87/00; Derivatives thereof
• CPC Class Codes: C09J 151/04 grafted on to rubbers
• CPC Class Codes: C09J 151/08 grafted on to macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: C09J 163/00 Adhesives based on epoxy resins; Adhesives based on derivatives of epoxy resins
• CPC Class Codes: Y10T 428/249952 At least one thermosetting synthetic polymeric material layer
• CPC Class Codes: Y10T 428/265 1 mil or less
• CPC Class Codes: Y10T 428/28 Web or sheet containing structurally defined element or component and having an adhesive outermost layer
• CPC Class Codes: Y10T 428/287 including epoxy group or epoxy polymer

Abstract

An activatable (e.g., heat expandable) material and articles incorporating the same is disclosed. The material includes an epoxy resin; an epoxy/elastomer hybrid or reaction product; a blowing agent; a curing agent; and optionally, a filler. In preferred embodiments, the material includes aramid fiber, nanoclay or both.

Claims

1. An adhesive expandable material, comprising:

greater than 40% by weight of an epoxy resin;

greater than 30% by weight epoxy/elastomer adduct, the adduct being a reaction product of an epoxy and an elastomer;

a fiber reinforcement material intermixed in the adhesive material; and

a nanoclay;

wherein the adhesive expandable material is substantially devoid of EMA and EVA.

2. An adhesive expandable material as in claim 1 wherein the expandable material is substantially devoid of acetates and acrylates.

3. An adhesive expandable material as in claim 1 wherein the expandable material is substantially devoid of thermoplastic polymers.

4. An adhesive expandable material as in claim 1 wherein the expandable material includes a curing agent and a blowing agent.

5. An adhesive expandable material as in claim 4, wherein the epoxy/elastomer adduct is an epoxy-carboxyl terminated butyl nitrile rubber adduct.

6. An adhesive expandable material as in claim 4, wherein the epoxy/elastomer adduct includes about 1:

3 to 3;

1 parts of epoxy to elastomer.

7. An adhesive expandable material as in claim 6, further comprising about 0.1% to about 4.0% by weight nanoclay.

8. An adhesive expandable material as in claim 1, wherein the expandable material exhibit a lap shear greater than about 2000 psi.

13. An adhesive expandable material as in claim 1, wherein the expandable material exhibit a lap shear greater than about 2000 psi.

9. An adhesive expandable material, comprising:

greater than about 40% by weight of an epoxy resin, the epoxy resin being substantially entirely a bisphenol A liquid epoxy;

greater than about 30% by weight epoxy/elastomer adduct, the epoxy/elastomer adduct being a solid epoxy-carboxyl terminated butyl nitrile (CTBN) rubber adduct;

fiber reinforcement material, the fiber reinforcement material being a pulped aramid fiber; and

about 0.1% to about 4.0% by weight nanoclay;

wherein the adhesive expandable material is substantially devoid of polymers acetate and acrylate polymers.

10. An adhesive expandable material as in claim 9 wherein the expandable material is substantially devoid of thermoplastic polymers.

11. An adhesive expandable material as in claim 10 wherein the expandable material includes a curing agent and a blowing agent.

12. An adhesive expandable material as in claim 11, wherein the epoxy/elastomer adduct includes about 1:

3 to 3;

1 parts of epoxy to elastomer.

14. An adhesive expandable material, comprising:

about 40% to about 60% by weight of an epoxy resin, the epoxy resin being substantially entirely a bisphenol A liquid epoxy;

about 30% to about 50% by weight epoxy/elastomer adduct, the epoxy/elastomer adduct being a solid epoxy-carboxyl terminated butyl nitrile (CTBN) rubber adduct;

a blowing agent selected from the group consisting of an amide and an amine;

a curing agent selected from the group consisting of polyamine and polyamide;

fiber reinforcement material, the fiber reinforcement material being a pulped aramid fiber; and

about 0.1% to about 4.0% by weight nanoclay;

wherein the adhesive expandable material is substantially free of thermoplastic polymers and the expandable material exhibits expansion to greater than 100% of its original size upon activation.

15. An adhesive expandable material as in claim 14, wherein the epoxy elastomer adduct includes about 1:

3 to 3;

1 parts of epoxy to elastomer.

16. An activatable material, comprising:

an adhesive expandable material including;

i) about 10% to about 70% by weight of an epoxy resin; and

ii) about 20% to about 50% by weight epoxy/elastomer adduct wherein the adduct is a reaction product of an epoxy and an elastomer;

iii) a fiber reinforcement intermixed within the adhesive material; and

iv) a nanoclay; and

a substantially tack free handling surface disposed upon the adhesive expandable material.

17. An activatable material as in claim 16 wherein the handling surface is provided by a layer disposed upon the adhesive expandable material.

18. An activatable material as in claim 17 wherein the layer is temporary.

20. An activatable material as in claim 17 wherein the layer is between about 10 microns and about 2 centimeters thick.

21. An activatable material as in claim 17 wherein the layer is less than about 1 centimeter thick.

22. An activatable material as in claim 17 wherein the layer is formed of a water based coating or a powder coating.

23. An activatable material as in claim 16 wherein the adhesive expandable material is substantially devoid of EMA and EVA.

24. An activatable material as in claim 16 wherein the adhesive expandable material is substantially devoid of acetates and acrylates.

25. An activatable material as in claim 16 wherein;

i) the epoxy resin is greater than about 40% by weight of th adhesive expandable material;

ii) the epoxy/elastomer adduct is greater than about 30% weight of the adhesive expandable material;

iii) the epoxy/elastomer adduct is a solid epoxy-carboxyl teminated butyl nitrile rubber adduct; and

iv) the adhesive expandable material includes a fiber reinforcement material.

27. An activatable material as in claim 16 wherein the adhesive expandable material exhibit a lap shear greater than about 2000 psi.

19. An activatable material, comprising:

an adhesive expandable material including;

i) about 10% to about 70% by weight of an epoxy resin; and

ii) about 20% to about 50% by weight epoxy/elastomer adduct; and

a substantially tack free handling surface disposed upon the adhesive expandable material;

wherein the handling surface is provided by a layer dispose upon the adhesive expandable material; and

wherein the layer is less than about 10 microns thick.

26. An activatable material, comprising:

an adhesive expandable material including;

i) about 40% to about 70% by weight of an epoxy resin;

ii) about 30% to about 50% by weight epoxy/elastomer adduct wherein the epoxy/elastomer adduct is a solid epoxy-carboxyl teminated butyl nitrile rubber adduct;

iii) about 0.1% to about 4.0% by weight nanoclay; and

iv) a fiber reinforcement material

a substantially tack free handling surface disposed upon the adhesive expandable material.