Two component (epoxy/amine) structural foam-in-place material
First Claim
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 component including at least one amine; and
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 said reactive mixture cures upon combining said epoxy component with said amine component through a cross-linking of said epoxy resin;
wherein one or both of the epoxy component and the amine component include an ammonium clay; and
wherein the ammonium clay is between about 2% and about 14% by weight of the epoxy component, between 5% and about 25% by weight of the amine component or both.
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Accused Products
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.
144 Citations
23 Claims
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1. A method for producing a foamed article, comprising the steps of:
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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 component including at least one amine; and 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 said reactive mixture cures upon combining said epoxy component with said amine component through a cross-linking of said epoxy resin; wherein one or both of the epoxy component and the amine component include an ammonium clay; and wherein the ammonium clay is between about 2% and about 14% by weight of the epoxy component, between 5% and about 25% by weight of the amine component or both. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 20, 21, 22, 23)
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9. A method for producing a foamed article, comprising the steps of:
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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; wherein the ammonium clay is between about 2% and about 14% by weight of the epoxy component and between 5% and about 25% by weight of the amine component. - View Dependent Claims (10, 11, 12, 13, 14)
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15. A method for producing a foamed article, comprising the steps of:
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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 tilled 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; wherein the ammonium clay is between about 2% and about 14% by weight of the epoxy component and between 5% and about 25% by weight of the amine component. - View Dependent Claims (16, 17, 18, 19)
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Specification