High elastic modulus structural foam materials with improved strain to failure

Patent metadata

Field	Value
Publication number	US-12202933-B2
Application number	US-201917263741-A
Country	US
Kind code	B2
Filing date	Aug 6, 2019
Priority date	Aug 6, 2018
Publication date	Jan 21, 2025
Grant date	Jan 21, 2025

Abstract

A material comprising at least about 10% by weight polyvinyl butyral, a thermoplastic epoxy, wherein the ratio of polyvinyl butyral to thermoplastic epoxy is about 1 to 10 to about 1 to 4, and at least 2% but less than 15% by weight adducted carboxyl-terminated polymer, wherein the material has a strain to failure of greater than 2% and a modulus of at least 700 MPa.

First claim

What is claimed is:

1. A material comprising:
i) at least about 10% by weight polyvinyl butyral;
ii) a thermoplastic epoxy, wherein the ratio of polyvinyl butyral to thermoplastic epoxy is 3 to 7 parts polyvinyl butyral to 1 to 2 parts thermoplastic epoxy; and
iii) a polymeric particle component present in an amount of at least 16% by weight of the material;
wherein the material has a strain to failure as measured by ISO 527 of greater than 2% but less than 7% and a tensile modulus of at least 900 MPa as measured by ASTM D638 Type IV test method when cured.

2. The material of claim 1 , including a curing agent for curing one part epoxy based adhesives at elevated temperatures.

3. The material of claim 2 , wherein the material includes a curing agent in the range of about 0.5% to about 5.0% by weight of the material.

4. The material of claim 2 , including a blowing agent.

5. The material of claim 4 , wherein the material exhibits a volume expansion from a green state to an expanded state of about 100% to about 500%.

6. The material of claim 1 , wherein the material contains from about 10% to about 30% by weight of polyvinyl butyral.

7. The material of claim 1 , wherein the material has a strain to failure of at least 3%.

8. The material of claim 1 , wherein the polymeric particle component is present in an amount of from 16% to 30% by weight of the material.

9. The material of claim 8 , wherein the polymeric particle component includes core shell rubber particles averaging about 200 nm in size.

10. The material of claim 8 , wherein the polymeric particle component is substantially free of agglomerated particles.

11. The material of claim 1 , including an epoxy/elastomer adduct.

12. The material of claim 11 , wherein the elastomer in the adduct is selected from styrene butadiene rubber, polysulfide, polybutadiene, acrylics, natural rubber, carboxyl-terminated butadiene-acrylonitrile (CTBN), polysiloxanes, polyester, urethane prepolymers, or any combination thereof.

13. The material of claim 11 , including carboxy-terminated butyl nitrile.

14. The material of claim 1 , wherein the material includes a blowing agent in the range of about 0.5% to about 5.0% by weight of the material.

15. The material of claim 1 , wherein the material when cured exhibits a tensile modulus from about 900 MPa to about 3000 MPa.

16. The material of claim 15 , wherein the material when cured exhibits a lap shear strength of at least about 400 psi.

17. The material of claim 1 , wherein the material exhibits a T-Peel strength when cured from about 4 N/mm to about 9 N/mm as a result of the combination of polyvinyl butyral, an adducted carboxyl-terminated polymer, and the polymeric particle component.

18. The material of claim 17 , including one or more reinforcing components, which may comprise mineral reinforcements.

19. The material of claim 18 , wherein the ratio of the adducted carboxyl-terminated polymer to the mineral reinforcement is from about 1 to 4 parts adducted carboxyl-terminated polymer to about 1 to 10 parts mineral reinforcement.

Assignees

• Zephyros Inc

Inventors

• Czaplicki Michael
• Madaus Keith
• Kosal David

Classifications

• C08L2207/53

  Core-shell polymer · CPC title

• C08L2205/03

  containing three or more polymers in a blend · CPC title

• C08L2203/14

  used for foams · CPC title

• C08L63/00 Primary

  Compositions of epoxy resins; Compositions of derivatives of epoxy resins · CPC title

• C08K2201/011

  Nanostructured additives · CPC title